Automatic Weld Edge Preparation 3D Processing with Plasma, Laser, Waterjet and Oxyfuel P

SOLUTIONS

Automatic weld edge preparation 3D processing with plasma, laser, waterjet and oxyfuel P. 8

PREMIERE: MSF Compact Here come the robots: Dome processing: Fiber laser reimagined Cutting range expanded Save valuable time now

Affordable entry into high- Our comprehensive product The basic step in production quality fiber laser cutting offers line of components for robotic of pressure vessels is the ultimate power package: working cells utilizes robots for precise cutting of tank ends. with its compact footprint manipulation, welding Automating this process to a and low maintenance and and cutting. Concurrently, a high degree while delivering operating costs, the new MSF new area unveils its potential high-precision cutting results Compact is perfectly suited for – direct integration of robots without the need of additional production of highly precise into CNC machine gantries surface finishing provides parts at high cutting speeds. for a variety of structural steel manufacturers with a clear applications. advantage and saves them a P. 30/31 P. 36 lot of valuable time. P. 20/21 The right solution for every cutting task

2D cutting Bevel cutting

Headquarters of MicroStep in Bratislava, Slovakia is the home of company‘s extensive R&D teams working on integrated development of mechanical and electronic nodes of CNC machines and control systems. “We provide solutions” MicroStep’s Managing Directors Alex Makuch and Eva Stejskalová

Pipe & profile cutting Dome cutting on the strengths of the company

The company MicroStep has already been active in chines were supplied with bevel cutting technology on their status sent back to ERP. Efficiency and reliability the cutting business for more than 25 years. Since our ▪▪ to deliver multi-functional solutions that streamline of the process is considered a matter of course. beginnings in 1991, and more so since the beginning the production process and save time for our cus- of our involvement with CNC cutting in the following tomers – almost 50 % of machines delivered in 2018 Realization of such complex projects depends on excep- year, our professional academic background from the integrated several different technologies tional technical solutions, reliability of their operation fields of automation and regulation has allowed us to ▪▪ to make bevel cutting a simple, fast and reliable and top-level service. Achieving of such goals would seek different approaches from those of traditional process with unified control for plasma, laser, oxyfuel not be possible without a strong developer base, strong machinery enterprises. MicroStep has pioneered and and waterjet – our unified interfaces and patented partnerships with our suppliers and global business successfully implemented a handful of novel solutions ACTG® technology delivered with all MicroStep bevel partners and most of all with the valued members of our that helped to improve the end user experience: a con- heads make beveling with our machines a highly distribution network. Together we make it happen. trol system interface running on Microsoft Windows®, precise and stable process, without maintenance a laser pointer for convenient tracking of cutting tool downtimes We hope you find inspiration while reading our magazine! position, automatic plate edge detection and plate size ▪▪ and many others: multi-functionality in laser cutting, measurement on plasma machines, auto-calibration of large-scale fiber laser machines, ABP with all cutting bevel tool stations (ACTG®) that not only guarantees technologies, automatic material handling systems long-term accuracy but also immensely simplifies their Plasma Laser Oxyfuel Waterjet maintenance, bevel tool stations with auxiliary axes for Our philosophy is to deliver machines that are not iso- accurate parallel cutting, Additional Beveling Process lated tools but form an organic part of the production Alex Makuch Managing Director (ABP) for beveling of thick parts that saves a great workflow by exchanging information, predicting break- MicroStep amount of material, mScan technology for 3D mapping downs and automating the material flow throughout of real dome shapes, advanced remote diagnostic and the customer’s production cycle. The key areas include remote control tools that reduce machine downtimes automation of processes in line with the ideas of IIoT and many more. Several of our solutions are patented. and Industry 4.0, and activities that improve the con- sistency of cutting quality, reduce the impact of human Supplemented with additional technologies: We are delighted that many of our ideas and visions errors and increase machine productivity. find appreciation by the industry, and that even some of • Drilling, tapping, countersinking the more recent ones are already becoming reality: Our customers who operate highly-advanced manufac- Eva Stejskalova • Marking turing facilities search for complex solutions of automa- Managing Director ▪▪ to establish automated bevel cutting as the process tion of cutting machines where the inputs are material MicroStep • Scanning of choice for all who require weld preparation on and task entries from their ERP systems and outputs are • Material handling www.microstep.eu parts – in 2018 alone over 50% of MicroStep ma- processed and sorted high-quality parts, with an update 3 3D processing with plasma, laser, waterjet and oxyfuel SOLUTIONS Page 08

Cutting with CNC machines, welding with robots: this is only possible with the highest precision in bevel cutting and, according Factories of the future: Digital transformation of to Doppelmayr, that is a unique feature of production machinery in line with IIoT, Smart MicroStep Industry and Industry 4.0 Page 14 Index Page 07

mScan: Unique technology sets standards in high-precision processing of dished ends MicroStep and Terex supplied MSF Max: The new laser flagship with 3D cutting solution debuted with Page 20 An interview with Eva Stejskalová, Mana- an automated production style in Chantiers de l’Atlantique ging Director of MicroStep and leader of line to China’s biggest mining Page 32 company’s software development teams equipment manufacturer Page 06 Page 38

Versatile options for beam and pipe processing: Automatic cutting machines for structural steel jobs Page 26 MicroStep’s co-founder and R&D chief Dr. Alexander Varga about the beginnings, a fruitful Here come the Robots: From robotic workplaces to robots for cutting of 3D shapes run and goals Page 36 Page 44

Thanks to excellent quality of bevel cutting: Irving gears up with MicroStep Introduction & Digitalisation Partnership with mountain conquerors expanded Pipe & beam processing Shipyard invested in a 16 m wide gantry with bevel technology 35 After 15 years of cooperation, the cable car market leader Doppelmayr embraces the technology from MicroStep 14 Here come the robots “We provide solutions” 3D solutions for steel constructions A broad portfolio: From robotic workplaces to robots for MicroStep‘s Managing Directors Alex Makuch and Eva Stejskalová Beveling and drilling are crucial Versatile options for beam and pipe processing: cutting of 3D shapes 36 on the strengths of the company 03 The job shop Prinzing invested into a plasma and oxyfuel Automatic cutting machines for structural steel jobs 26 combination with a handful of complementary technologies 16 Robotic pipe cutting Transforming the European manufacturing industry “We no longer need to outsource” More flexibility for the Jan De Nul Group: An innovative combination An interview with Eva Stejskalová, Managing Director of MicroStep Additional beveling with oxyfuel Bevel cutting of beams, pipes and plates: Innergy Heavy of plasma sheet cutting and oxyfuel cutting of pipes by a robot 37 and leader of company’s software development teams 06 The leading Spanish earthmoving equipment manufacturer Industries chose versatility and reliable service 27 Solintal “turns projects into reality” 19 40 percent production increase Factories of the future “The machine runs very well“ MicroStep and Terex have supplied an automated production The inevitable challenge: Digital transformation of production The French company Mecasem relies on MicroStep‘s technology line for the Chinese mining equipment manufacturer ZMJ 38 machinery in line with IIoT, Smart Industry and Industry 4.0 07 for sheet and pipe processing 28 Dome processing Machine Production Management (MPM) Market leader trusts MicroStep Automating the production process on cutting machines 39 Pipe cutting machine for the Chinese Gree Group: the world‘s Beveling Dome cutting expert largest manufacturer of air conditioning solutions 29 mScan: Unique technology sets standards in high-precision processing of dished ends 20 Industry-proven beveling solutions About MicroStep 3D processing with plasma, laser, waterjet and oxyfuel 08 MicroStep mCAM Fiber laser solutions CAM solution for cutting of 3D parts 22 Additional Beveling Process Machine series ABP: Additional weld preparation with gantry-type CNC Processing time greatly reduced The fiber laser experience The right machine for every cutting task 40 cutting machines – efficient alternative to robots 11 Brewing equipment specialists GEA accelerate their production with a MSF product line offers multi-functionality and versatility 30 combined plate and dome cutting machine 23 Accessories “All expectations fulfilled!“ Successful launch of MSF Max at the traditional French cruise ship builder The right tool for every task 42 stürmsfs AG, one of the most modern steel and metal processing Substantial time saving Laser flagship with bevel cutting solution debuted with style in job shops in Europe, invested in a complex MG machine 12 The Hungarian pressure vessels manufacturer Faddikorr Chantiers de l’Atlantique 32 Invest in innovation and production benefits from state-of-the-art dome cutting process 24 Dr. Alexander Varga, co-founder and MicroStep’s R&D chief A good experience about the beginnings, a fruitful run and goals 44 Metallbau Striegel have decided for a waterjet-plasma cutting New system replaces two machines combination with a pipe processing option 13 Domes from Slawinski are in demand all over Europe – the company The MicroStep Group uses MicroStep‘s technology to cut them 25 Automation & Innovation State-of-the-art solutions for processing of plates, pipes, profiles, beams and domes 46 CNC cutting systems for large-scale applications The MicroStep World MicroStep partners with global welding automation expert Present in more than 50 countries worldwide 47 Pemamek for advanced shipyard projects 34

4 5 Transforming the European manufacturing industry An interview with Eva Stejskalová, Managing Director of MicroStep and leader of company’s software development teams

Mrs. Stejskalová, you are MD of MicroStep and from your of innovation laggards who will fight to stay relevant in position you supervise the areas of finance, innovation the long term. For MicroStep it is a huge opportunity, and software. In your opinion, what are the factors that as the company has always been investing heavily into make MicroStep one of the technology leaders in the development of its own control systems and software, cutting industry also in future? and so it is well prepared to take the path to digital innovation. Eva Stejskalová: MicroStep entered the cutting business as Digital innovation – what does a university spin-off with exten- it mean in context of cutting Factories of the future sive experience and know-how “At present the pace of business? in automation technology. With its strong research and devel- Eva Stejskalová: Digital opment capabilities the com- technological change technologies can address all The inevitable challenge: Digital transformation of production pany was able to meet even sorts of challenges that cutting those customers’ requirements is faster than ever…“ businesses face nowadays – which were previously consid- demand for productivity and machinery in line with IIoT, Smart Industry and Industry 4.0 initiatives ered unfeasible by incumbent quality enhancement, or lack companies. Until now the most of skilled operators. Some innovative solutions result from concepts like the “connected During recent years, while facing ever-growing de- cessfully running at one of MicroStep’s Dutch customers machinery such as automatic cranes, storage towers, close cooperation between factory” are widely known and mands for greater efficiency, faster manufacturing, – the maritime service provider Neptune Shipyards. loading and conveyor systems as well as controlling customers with visionary Eva Stejskalová accepted already. Real-time further cost reduction and resource conservation, the The system significantly reduces manipulation time these processes and exchanging data with different concepts of their production Managing Director production and inventory data industry has witnessed a paradigm shift concerning and allows for expansion with other cutting machines devices, ERP systems and cloud solutions. Our machines MicroStep facilities and MicroStep which enable efficient planning and the future development of industrial engineering. and storage towers in the future. The automation is in are ready to provide detailed data to the upper control is ready to take challenges and scheduling processes. People Digitalization and digital transformation are the loading of particular pallets with pre-loaded plates into level. We are closely watching the developments in the turn their visions into reality. responsible for monitoring cut- buzzwords, along with IIoT, Industry 4.0 and others, two cutting machines automatically and unloading of field and also actively participating in several related However, at present the pace of technological change ting production can do so remotely without being phys- that fuel the underlying discussions and activities both the pallets back to the storage tower after the cutting/ initiatives, with the aim not only to be prepared for the Eva Stejskalová, is faster than ever and particularly digital technologies ically present on the shop floor. MicroStep delivers such in academic and commercial spheres. More precisely, marking processes are finished. The prerequisite for upcoming challenges but also to help shape the indus- Managing Director of MicroStep have already shown immense potential to shape manu- functionality with its Machine Production Management a change for the better should come as a result of such automated material handling is the ability of the try of the future. facturing industries. This trend can shatter the position software and the MicroStep Dashboard. But digital tech- smart project management and transformation of the machine to automatically measure the location and nologies can offer much more. Machine learning will production process towards automation and interop- rotation of the plate compensate for the lack of skilled operators as decisions erability of production means, as well as the ability on the table by a plate and actions can be based more on data analysis and to implement predictive maintenance. There is a long edge detection sen- less on experience. Parameter adjustment or tool wear way ahead but the foundations have already been laid sor. Integration of a forecast is an example. In order to gain insight a big – MicroStep has been building its systems with these CAPP software is also amount of data must be collected from the process and basic ideas in mind for at least a decade. recommended as it analysed through complex mathematical models and allows to automatical- algorithms to identify patterns and trends. Based on the Over the past years, the company’s in-house developed ly load cutting plans results the machine can make autonomous decisions. In solutions for machine-to-machine and machine-to-en- generated for the case the correct algorithms are used, machines will learn terprise communications have been winning increasing currently loaded mate- faster and more reliably than a human being. interest and gaining adoption in enterprises throughout rial and to initiate the Europe, Asia, America and Australia. Integration of our cutting process auto- Do your customers realize the potential of digital technol- equipment with existing production workflow and ERP matically, if required. ogies for their business? systems allows our customers to interconnect MicroStep MicroStep supplies its cutting machines with their existing machinery by both own production man- Eva Stejskalová: Yes, the vast majority of companies hardware and software interfaces and to exchange agement software un- realize the benefits, but many of them think they lack data. We have implemented a number of automation der the name Machine the resources needed for their digital transformation. It solutions and machine-to-machine interfaces, especially Production Manage- is necessary to understand that fully digital factories are in large-scale productions, integrating several cutting ment (MPM, for more still rare and the digital transformation can be phased machines along with automated material handling sys- info see p. 39). Thanks depending on the possibilities of an individual company. tems. Further such projects, and more complex ones, are to the automation, For example, hardly anyone would challenge the fact scheduled for delivery in the near future. technologies that do that unexpected equipment breakdown is a major threat not require the over- to manufacturing revenues. Advanced data analytics Flexibility is another trend shaping most industries. It sight of an operator together with machine learning can be used to monitor is a result of increasing demands for a wide range of (e.g. inkjet marking) whether a piece of equipment is prone to failure and more customized product variants. “Lot size 1” is the may run completely predict when it will breakdown, thus preventing unex- ultimate goal. To be able to realize diverse projects in without supervision – pected downtime. However, relatively simple centralized production efficiently, it is advisable for a manufactur- all the plates that are monitoring of operating hours and scheduling of pre- er to have a set of versatile means of production that loaded in the storage ventive maintenance can also bring major benefit. ensure smooth production transition between different tower can be marked projects. Additionally, a high degree of automation, a automatically during I can see that digital technologies are an extremely good selection of technologies and the capability to the night. In case of complex topic. How will MicroStep cope with research and process various sizes of workpieces are required. In line a forced interruption development in so many areas? with the abovementioned trends, MicroStep’s cutting of the process, the machines are designed to be actively integrated into machine will notify the Eva Stejskalová: This is the age of open innovation. centrally managed production systems by automating operator via an e-mail MicroStep has a long history of collaboration with the the material flow (e.g. via feeding/lifting equipment and or text message. Slovak University of Technology in Bratislava and our conveyors) and by software that enables the machines joint projects significantly supported product develop- to communicate with different applications of the Another example of ment in our company. production management system, such as stock-, order- such a complex solu- Above right: A production line interconnecting cutting Nowadays open innovation goes beyond simple collab- and part databases as well as with external ERP systems. tion is a fully automatic cutting/marking line consisting machines with an automatic pallet exchange system and a oration between two entities and that is why MicroStep The goal is for the machine to be able to quickly adapt of eight cutting machines, an automatic crane, a loading tower pallet storage for plates allows for 24/7 operation. actively participates in designing a pan-European to different cutting/processing requirements, increase wagon and two output conveyors, that is fully managed Above left: CAPP-enabled MicroStep automatic innovation community of 50 companies, universities, and work efficiency, optimize the production process and by MPM software and capable of processing 500 tons production line uses advanced machine management research institutes focused on added-value manufactur- minimize costs and risks – the whole production should of steel per day (for more info read the story about our software MPM to boost production efficiency. ing. If the project succeeds in receiving funding from the be fast, smooth and transparent, monitored (at first) Chinese customer ZMJ on p. 38). In the middle: Representatives of MicroStep at the annual European Institute of Innovation and Technology, Micro- from the corporate network. congress focused on Industry 4.0 solutions „Fertigung 4.0“ Respected Expert: As a member of the High-level Strategy Group on Industrial Technologies within the EU Research and Step will have a chance to contribute to the concerted It is understood that digitalization of production means in Bavaria, Germany (2017). Innovation programme Horizon 2020, MicroStep CEO Eva Stejskalová is advising the EU Commission on Key Enabling effort aimed at transforming the European manufactur- An example of such project is a modular combination is a matter of broad consensus on standards within the Below: Automated laser cutting machine with automatic Technologies (above). Great honor for MicroStep: Eva Stejskalová and company founder Dr. Alexander Varga were announced ing industry into the most sustainable and competitive of cutting/marking machines and an automatic pallet industry and beyond. At this stage, MicroStep has had material loader and additional input conveyor managed by EY Entrepreneur of the Year™ 2014 in Slovakia by the “Big Four” consulting and auditing giant EY (below). industry world-wide. exchange system with a storage tower, which is suc- several years of experience in interfacing to third-party MPM. 6 7 ❶ ❷

❸ ❹ The area of bevel cutting has been one of priorities temporary beveling tool stations. The benefits – greater hand with the third-party development of energy-beam and an integral part of MicroStep’s R&D for many precision along with significant savings of production sources and our implementation of the latest cutting years. We acknowledged the importance of this tech- time and capacities – easily outweigh the higher initial technologies developed by our suppliers. Thanks to this nology for streamlining of the production process and investment. Moreover, in automated preparation of background, we are today able to offer a comprehen- realized that many fields of the engineering industry beveled edges on 3D objects such as domes, pipes, sive bevel cutting solution for a wide range of materials would greatly benefit from its proper development. rectangular or IPE profiles, the use of specialized tool and thicknesses. Thanks to our long-term focus and experience we stations on gantry-based machines brings a great finan- were able to continuously innovate the equipment cial benefit compared to the commonly used robots. Our comprehensive beveling function and supporting and, furthermore, develop new technologies that se- functions such as torch geometry calibration and adap- cured MicroStep a stable place among market leaders Since the introduction of our plasma rotator in 2000 tive bevel compensation allow our customers to cut in bevel cutting. and a waterjet rotator in 2001, MicroStep has made bevels in a convenient way using different cutting tech- continuous efforts to establish automated CNC bevel nologies – plasma , laser , waterjet and oxyfuel According to field studies, up to 50 % of parts pro- cutting as a common and highly efficient production – as well as to create bevels in a wide material thick- ❶ ❷ ❸ duced in the CNC cutting industry worldwide need to technology for preparation of weld edges on differ- ness range reaching from 5 mm to 300 mm (depending ❹ have beveled edges, yet only a considerably smaller ent types of materials. Our goal is to deliver cutting on the used cutting technology). Furthermore, thanks percentage of machines is equipped with bevel tool machines that can produce cut parts with bevels in to unique features of our in-house developed control stations. The reason may be the additional cost of this convincing quality and precision, yet the operation of system iMSNC and a profound knowledge of different advanced equipment, but mainly it is still a relatively low the machines is kept reasonably simple. Throughout the cutting technologies, MicroStep machines are capable awareness of decision makers in engineering companies years, improvements of mechanics and motion control of combining various technologies (e.g. plasma and about the possibilities, availability and reliability of con- of our rotary- and 3D tilting tool stations went hand in waterjet) within a single cutting plan .

❺

Alexander Varga, Ph.D. Head of R&D Industry-proven MicroStep “In the development of our bevel cutting equipment, the requirements of high precision, beveling solutions repeatability and long-term process reliability have always 3D processing with plasma, laser, waterjet and oxyfuel been at the forefront.“

❺ ❺ ❶ 9 Additional Beveling Process ABP: Additional weld preparation with gantry-type CNC cutting machines – an efficient alternative to robots

Robots are widely regarded as irreplaceable when it equipped with one of MicroStep’s bevel cutting tool comes to weld preparation and bevel cutting on al- stations and an additional scanner unit. The unit can be ready cut parts. MicroStep has brought an alternative attached to the bevel bead or mounted on a separate to the market, which has seriously shaken the robots’ tool station – depending on the particular machine ❻ position in this regard. This innovative technology is configuration and desired application. called ABP – Additional Beveling Process and it allows very precise subsequent beveling with gantry-type The process then unfolds as follows: First, a 2D drawing CNC cutting machines. of the pre-cut part is imported into MicroStep’s CAM software AsperWin®. The machine operator defines the Subsequent weld preparation is a standard procedure required bevels in AsperWin’s user-friendly interface. for cut parts in many areas of the metalworking indus- The system then generates a cutting program for addi- ABP scanner determining the exact position of a part try. Manufacturers of machinery and materials for power tional beveling. To find the exact position of the part on placed on a random spot on the cutting table. plants, turbines, pumps, mining equipment equipment the cutting table, the machine will use the ABP scanner. and others often work with very large steel thicknesses, During the scanning process, the real contour of the so the parts cannot be immediately cut with bevels – part is compared with its ideal shape from the drawing either due to technology limitations or because it would and if slight differences are detected (a real part is hard- mean a significant waste of material. ly ever completely accurate), the system will align the cutting program with the real shape to achieve the most Alternative to conventional processes accurate cutting result possible. After the starting point of cutting is verified, the cutting process begins. The In case of big material thicknesses, bevel preparation on system can make V, Y, X and K bevel cuts (whereby for ❼ parts has traditionally been a two-stage process. First, K and X cuts the part needs to be turned and scanned MicroStep machines provide two types of beveling parts with very high demand on accuracy. the desired contour is cut on a conventional cutting again after the first cutting round is completed). Obvi- processes: Accuracy of the cutting technology is enhanced by machine with a straight tool, e.g. by plasma or oxyfuel. ously, the technology allows to scan and process parts Then, the cut part will be taken out and moved to an- made with completely different technologies – for ex- DBP – Direct beveling process – represents the classic eliminating beam deviations that occur naturally when During the scanning process, the real contour of the part other workplace, where it will be processed by a robot, ample, thick parts cut with oxyfuel can be subsequently way of bevel cutting where the bevel is cut directly into the torch is in a tilted position in relation to the material is compared with its ideal shape (drawing). the raw material (sheet , pipe , profile or dome). and cause an unwanted difference of the cut angle from which will add bevels to the contour in preparation for a beveled by plasma, or parts pre-cut with plasma can The cut edge of required shape – A, V, Y, X or K – is cre- the theoretically programmed slope . subsequent welding process. be cut with ABP by fiber laser. Thanks to MicroStep‘s ated via multiple consequent❻ transitions❼ of the cutting “The initial question we asked ourselves was why unified concept of bevel cutting equipment and its easy ® tool (at different angles) along the cut edge. MicroStep ABC – Adaptive bevel compensation⓫ – is an advanced you should require a robot for the subsequent weld setup via the patented ACTG technology, the ABP pro- machines with two rotators allow cutting of two identi- feature of iMSNC for compensation of such beam preparation in the first place,” explains Alexander Varga, cess is fast, reliable and easily applicable to all cutting ❽ cal parts using two rotary heads at once . The current deviations. ABC enables implementation of databases development chief and co-founder of MicroStep. “Our technologies – plasma, laser, oxyfuel as well as waterjet. maximum bevel angle of supplied tool stations is: 52° of compensation angles and other values for various cutting machines have all the means for achieving high- (More details on ABP with oxyfuel technology can be for plasma, 45° for laser, 65° for oxyfuel and❽ 45° for cutting technologies (e.g. Hypertherm´s True Bevel™ ly precise bevel cuts.” found on p. 19.) waterjet. technology). The compensation values can also be ad- ABP – Additional beveling process – enables adding justed directly by the machine operator . Based on MicroStep‘s long-term experiences in bevel New process provides significant advantages of bevels to parts that have already been cut with a cutting and process control, the company developed a straight tool by plasma, laser, oxyfuel or even waterjet And finally, to ensure precise following ⓬of the material technology involving laser scanning of parts along with Compared to additional processing of pre-cut parts software tools that enable programming of additional with a robot, ABP technology offers several clear advan- (for further information see page XY). surface during plasma bevel cutting with the torch po- With rotator from MicroStep, V-, Y-, and (under certain sitioned always in the correct cutting height, MicroStep bevels on parts. The process was named ABP – Addi- tages: the complete process (2D cutting and additional tional Beveling Process. ABP proves to be superior to beveling) can be done with the same machine – this conditions) also X- and K-cuts can be produced additionally Generally, the accuracy of bevel cutting is determined developed a smart height control system: on already pre-cut parts. by mechanical accuracy of the cutting machine, accuracy the standard two-stage process in terms of efficiency saves space in production and, above all, the time that is of the cutting technology and the stage of development STHC – Self-teaching height control – a combination as well as quality. And it comes with only a fraction of otherwise spent with part manipulation. In addition, the of applied algorithms of control of the torch distance of 3D motion control, self-teaching algorithms and the investment cost that would be needed for a robotic cost of adding a laser scanner to a MicroStep cutting from the cut material. adaptive height control according to the plasma arc workstation. machine is significantly lower than the investment in Apart from consistent use of high-quality components, voltage. STHC ensures positioning of torch in the cor- a separate, dedicated robotic workplace. On the other the mechanical accuracy of MicroStep bevel cutting rect height at any angle (e.g. during cutting of variable ABP: Laser scanner opens up new possibilities hand, cutting results that can be achieved on a gan- machines is provided by several advanced solutions: bevels). try-type machine are more precise due to the generally In order to enable a MicroStep machine to use the higher rigidity of the cutting machine. ITH – Intelligent torch holder – ensures protection of All the described functions greatly contribute to im- additional beveling function, the machine has to be the torch in case of an accidental collision. Its slip-back provement of accuracy of the bevel cutting process. function ensures return of the torch into the correct Our more than 700 beveling tool stations and 350 ACTG position after elimination of the collision. The ITH body systems supplied in the field and first of all the excellent Thanks to high rigidity of the cutting machine, the cutting includes an advanced sensor system for detection of bevel cutting results achieved on MicroStep machines results are finer and more precise than with a robot. the exact torch position and provides also the endless tell the story by themselves. rotation function.

ACTG – Auto-calibration of tool geometry – secures that during rotation and tilting of a rotator the torch tip always stays in the required (exact) position.❾ The ACTG system consists of a calibration station , a torch extension probe and advanced control software. ACTG eliminates the necessity of mechanical adjustment❿ of the bevel head and significantly reduces setup time of the machine from several hours to a couple of minutes.

❾ Compensation of longitudinal displacements – an optional function which ensures absolute accuracy Close-up view of a cut part with added bevels. of the cutting machine in the longitudinal direction. During installation, the machine is measured by a laser interferometer and the measured values are used for calibration of the positioning system. The measurement EXTRA can be applied upon request in case of cutting of long ⓫ ABP

ABP for stainless steel and aluminium Video presentation: ABP with plasma can be used for not only mild steel parts but also for stainless steel or aluminium. As an example, the 15 mm thick stainless steel part pictured above was beveled in a 130 A plasma cutting process. ”The dross is easy to remove. The technology provides impressive results. Especially with stainless steel, it saves a lot of material and also handling costs,” says Alexander Varga, development chief of MicroStep. “For bigger thicknesses, the material savings achievable thanks to ABP are very attractive.”

www.microstep.eu/video

10❿ ⓬ 11 A good experience Metallbau Striegel have decided for a waterjet-plasma cutting combination with a pipe processing option

Maschinen- und Metallbau Striegel GmbH from south- ern Germany supplies its customers from many different industries with a wide variety of products. In order to fulfill all the orders on time, the managing director Joachim Striegel has decided to invest into a combined CNC waterjet-plasma cutting machine from MicroStep.

Kenzingen, 30 kilometers north of Freiburg is often called “Pearl in Breisgau“. More than 10,000 inhabitants and many visitors like to stroll through its historic old town and it is also the place where employees of Maschinen- und Metallbau Striegel GmbH go about their work with great passion and skill. In 1991, Joachim Striegel founded the company because he always wanted to stand on his own feet as he revealed during the interview. Striegel‘s “All expectations fulfilled!“ customers appreciate the results of cutting and joining steel and stainless steel as well as their production of complete assemblies. “If someone needs quick help, then stürmsfs AG, one of the most modern steel and metal processing they come to us,” says Managing Director and founder proved to be no longer adequate because operation and The machine runs seven days a week from 7 am to 11 Joachim Striegel. loading took too much time and limited the production. pm. Mr. Striegel is satisfied: “The new machine is exactly And so, Striegel considered several offers for new equip- like I imagined it.“ job shops in Europe, invested in a complex MG machine The requirements are as diverse as the customers: ment and eventually decided to invest into a combined pharmaceutical industry, food and beverage industry, CNC waterjet-plasma cutting machine from MicroStep. “I tunnel technology or heavy engineering. The expecta- made that decision because I had good experience with Waterjet stürmsfs AG is considered one of the leading job shops of the order and manufacturing to delivery – is one of the “The machine is two to three times as productive as its tions Joachim Striegel and his team have to meet are MicroStep.” Video presentation: in Switzerland and one of the most modern across Eu- company‘s many strengths. Just to give an example, the predecessor.” very high. The company has corresponding demands rope. This steel and metal business is well prepared to major customers have individual access to stürmsfs´ sys- on its machines. About ten years ago they started to The AquaCut 6001.30WWrkP from MicroStep is equipped take care of all jobs, both complex and short-term. For tem in order to achieve fastest results possible. “We are Since July 2017 the machine has been in use for two use waterjet cutting. with a waterjet rotator for cutting bevels up to 45°, a this reason, the company has invested heavily in recent absolutely flexible in production,” says Meier who sees shifts per day and when it is necessary, a third, night, second straight waterjet head and a plasma cutting head years, into digital systems, automation, and cutting the increasing number of short-term orders as the major shift is added. The job shop has bought a plasma cutting Later on, Striegel invested into a plasma cutting machine for underwater cutting. It also has a pipe cutting channel. edge technology. Since July 2017, this includes also the challenge for the entire job cutting industry. “You know system enabling both 2D and 3D plasma cutting, drilling, from MicroStep. However, over time, the solution with With a large work area of 6,000 x 3,000 mm the machine www.microstep.eu/video MG plasma cutting machine from MicroStep. stürmsfs what is going to be cut this week but often you have no tapping and countersinking. The working area of 21 x 3,5 two cutting machines utilizing different technologies can bevel cut and mark plates and pipes of various sizes. relies on this multifunctional cutter for 3D processing of idea what the week after that will be like. The contractor m, divided into two cutting zones, allows processing of sheet metal with a plasma rotator, 2D plasma torch and has to be prepared to cut large orders on a short notice.” large-format plates in parallel operations – while in one drilling spindle. Automated processes and increased digitalization of zone the material is being cut, the other one is safe for production should be a big help in this regard. The core unloading of cut parts and loading of new material. The Nestled between the hilly Appenzellerland and Lake Con- of the company‘s success is still the “know-how” of its job shop is usually cutting plates between 5 and 35 mm stance, Goldach is regarded as one of the most attractive employees coupled with the machinery which leaves thick. Both the drilling spindle and the plasma rotator regions in Switzerland. Amidst this picturesque scenery room for flexibility that in turn enables the necessary with infinite rotation are being used quite often. The is one of the most modern steel and metal processing speed while maintaining required quality. decision has proven to be the right one also for the plate job shops in Europe that helps make the Goldach region production manager Markus Egger: ”We are very satisfied one of the most efficient providers of complete steel and Wanted: Technologically advanced plasma cutting sys- with the machine. Especially when it comes to drilling, it is metal solutions on the Swiss market. 40 thousand tons tem with bevel cutting and drilling two to three times more productive than its predecessor. of metal and steel wait at different locations, including We have a great advantage, we are able to cut threads, fully automatic high shelf warehouses, ready to be cut, As a part of a large-scale production optimization project, we are able to countersink. Both accuracy and quality of processed and delivered every day. the company decided to build a new hall for thermal cut- bevels are very high.” ting. Their now five-year-old plasma cutting machine was A total of six facilities in Switzerland, Austria and Slovakia to be supplemented with a second one in order not to af- Switching to MicroStep technology worked “very well” employ around 260 employees responsible for produc- fect the current plasma cutting orders. After an extensive tion of customized components. Small locksmiths, steel analysis of the market as well as the technical possibilities The switch to MicroStep was accompanied by the change construction builders, large manufacturing plants, all and considering their particular needs, stürmsfs finally to the SigmaNEST CAD/CAM software made by an depend on the stürmsfs AG’s high-quality products and decided in favor of a plasma cutting machine MG from American nesting specialist. Marcel Meier is satisfied: “We their on-time delivery ensured by their own truck fleet. MicroStep. “We were convinced by the whole package. have taken some risks because we had to change both “It is the diversity that makes our company so important From the start we had an impression that the bevel head the machine and the nesting software provider at the that we are considered the most established steel and we are getting is state-of-the-art.” says Marcel Meier same time. And the whole change with MicroStep worked metal dealer in Switzerland. We are competent in many looking back at the purchase decision at the end of 2016. out very well,” says the head of Projects and Corporate areas like machining and thermal cutting. We are also In addition, performance of the drilling unit has also Development who played a major role in the investment known for a high degree of automation. We function as proven to be most convincing. “This is where MicroStep is decisions. a detached workbench of the customer.” Marcel Meier, far ahead compared to other CNC machine producers.” Head of Procurement & Corporate Development, ex- This project has left behind many happy faces among the plains. Since July 2017 the machine has been in use for two responsible people from stürmsfs AG. “The system is very shifts per day and when it is necessary, a third, night, productive and reliable – it has met all our expectations,” Large orders on a short notice shift is added. The job shop has bought a plasma cutting says Marcel Meier. “Our operators appreciate that they system enabling both 2D and 3D plasma cutting, drilling, can actively influence the cutting result.” Automation of the whole production cycle – from placing tapping and countersinking.

Markus Egger stürmsfs Head of Sheet Metal Division stürmsfs AG Video presentation:

“We are very satisfied with the machine! The accuracy and also the bevels are of a very high quality.“ www.microstep.eu/video

12 Partnership with mountain conquerors expanded Cutting with CNC machines, welding with robots: this is only possible with the highest precision in bevel cutting and, according to Doppelmayr, that is a unique feature of MicroStep

The Doppelmayr/Garaventa Group climbs to the globe at lofty heights and connect people with cities it is necessary to keep relying on new technologies in cess needs to be very accurate because we then weld cut about 13,000 tons of sheet metal every year in the highest and most remote corners of the earth, trans- and nature through innovative transport solutions. In 95 production,“ says Mr. Eberle. about two thirds of the components with robots. That‘s recent past. According to Mr. Eberles‘s estimate, 18,000 porting skiers, vacationers or daily commuters. For countries on six continents, several thousand cable car The Doppelmayr/Garaventa group has experienced why we need a tolerance of maximum ±0.5 mm here. tonnes in a three-shift operation are now possible. “We 17 years, the market leaders in cable car construction installations are in use every day. It is no coincidence another such success in the recent past. During the last This is a very, very high requirement for this thermal will cut more in the future. When we build more prod- and MicroStep have maintained a close partnership. that the company has been the market and technology two years, their entire cutting department has been process,“ emphasizes Walter Eberle. ucts, we need the capacity in order to cover the ever In the hunt for steady improvements, their reliable leader for more than half a century. “Foresight, trend fundamentally modernized. The global group relied on increasing number of production peaks. This is the first production line has been recently completely renewed. recognition, innovation. These are the strengths that MicroStep‘s solutions – as has been the case for more Leading technology, good experience and service step in production and we must not fall behind. So we Thus, Doppelmayr increased its flexibility in cutting, its Doppelmayr‘s customers can rely on. We have been than 15 years now. At the turn of the millennium, Dop- proximity all speak for MicroStep still have a good reserve for the future,“ says Mr. Eberle. precision and the production speed. working together well with many of them for decades. pelmayr was looking for a suitable job cutting provider This enables us to set milestones again and again,“ says but was unable to find one that could make the up to With that in mind, the decision-making group of Special solution saves manipulation time and increases A turquoise shimmering sea, glittering sandy beaches, Walter Eberle, explaining the strengths of the group. He 5,000 parts they needed daily. “So, we had to search for Mr. Eberle and other production managers searched precision palm-covered islands - the sight that Vietnam vaca- works as a deputy production manager in production a supplier of cutting equipment and, fortunately, ended extensively on the market, visited trade fairs and took tioners have been enjoying for a few months on a planning at Doppelmayr‘s headquarters in Austrian up at MicroStep,“ Mr. Eberle looks back. The decision a close look at technology demonstrations. In the end, Each of the two cutting machines was also equipped 5 ride on the longest cable way in the world is peerless. Wolfurt on Bodensee Lake. was easy to make: Doppelmayr wanted a single supplier the decision fell again on the world‘s market leader in with a CCD camera . This determines the exact posi- 7,899.9 meters connect the two holiday islands Phú for software, controls, drilling and cutting machines. automated plasma cutting. “There were several criteria tion of holes already drilled into the plate, on which the ❹ Quốc and Hòn Thơm in the south of the country and, at Exciting projects can only be implemented with MicroStep was the only company to offer such complete that were crucial. We have had good experience togeth- nested cutting plan is then automatically aligned. As a the highest point, the cable car takes visitors to 164 me- modern technologies solution. And so, the 60-meter-long production line did er for fifteen years, the service proximity of MicroStep result, the material can be precisely cut in exactly the One of the four cutting gantries at Doppelmayr is equipped ters. This is just one example of Doppelmayr/Garaventa almost two decades of good work – until came the time in Bad Wörishofen was also an advantage and in terms correct relation to the already drilled holes. “Because with four oxyfuel cutting heads for cutting of big material Group‘s projects. The company‘s history is characterized There are always new and exciting projects on Eberle‘s to modernize it. The main requirement was to increase of bevel cutting quality, MicroStep has a unique selling all of these technologies are available to us on one thicknesses. The more than 60-meter-long production line by innovations, records and superlatives. Adjectives such desk. The market demands ever shorter delivery times the precision of bevel cutting so that no problems point when it comes to complying with the required production line, we save on a lot of time-consuming runs in three shifts at the headquarters of the company in as “longest“, “greatest“, “highest“ and more adorn the for increasingly individualized solutions. “As a market would occur during subsequent automated robot weld- tolerances.“ material handling that is without added value,“ explains Wolfurt (Austria) near the Bodensee Lake. headlines of richly illustrated articles in newspapers and and technology leader, it is of course our goal to always ing. In addition, the new purchases should provide more Mr. Eberle. magazines. Cable ways open up remote corners of the maintain the highest technological level. To achieve this, flexibility, productivity and efficiency. “Our cutting -pro In mid-2016, the production line was gradually renewed. Implemented were: a drilling unit with a gantry and The entire production line has been completed by com- automatic tool changer and two cutting machines missioning of the last machine in December 2017. Ever with a total of four gantries. Three cutting gantries since, it has been running in a multi-shift operation from ❶ + are each equipped with a plasma rotator, a 2D day one. It was a worthwhile step for Doppelmayr/Gar- ❷ plasma cutting head and two oxyfuel cutting heads. The aventa Group. Walter Eberle is convinced of this – after ❸ fourth cutting gantry has four cutting heads for parallel more than 15 years of cooperation. “It distinguishes the oxyfuel cutting . “It worked the way it was supposed company, shows that it seeks progress and does not to from day one,“ says Mr. Eberle. The three identical rest on the deserved success and continues to look for ❺ cutting gantries bring more flexibility. Doppelmayr has what can be improved.“

2 Walter Eberle 3 Production Planning Doppelmayr Seilbahnen GmbH

For the company Doppelmayr MicroStep installed a powerful drilling machine of the DRM series and two plasma and 1 oxyfuel cutting machines of the MG series with two gantries + each. The two MG machines❶ are each equipped “We have had a good experience with a CCD camera for maximum precision when cutting together for fifteen years. When it comes Doppelmayr pre-drilled❷ ❸ parts. Video presentation: ❹ to bevel cutting quality, MicroStep has a unique selling point in complying with the tolerances required for robot welding.“ 4 www.microstep.eu/video

14 15 Beveling and drilling are crucial The job shop Prinzing invested into a plasma and oxyfuel combination with a handful of complementary technologies

In order to renew its machine park and to be- right cutting solution, Hans Prinzing‘s management has come faster and more flexible in production, the decided to purchase a combined plasma and oxyfuel Baden-Württemberg based company MAP Prinzing machine with supplemental drilling technology. “We Brennschneidtechnik GmbH was looking for new cut- looked at the entire market and also attended several ting machinery. The job cutting business found their technology demonstrations. All the technology com- solution at MicroStep – and invested into a complex binations were known beforehand. The decisive factor CombiCut machine. This multi-functional system for MicroStep was the bevel cutting equipment and the enables bevel cutting with plasma, 2D oxyfuel cutting, drilling unit. The drill was the most powerful among all drilling, tapping, countersinking and marking with a competitors,“ Hans Prinzing looks back. powerful combination of two gantries. And so, in order to achieve maximum flexibility in About 50 kilometers east of Stuttgart in Germany lies production, the company Prinzing opted for a special the Baden-Württemberg municipality of Gingen an der solution which integrates two gantries in one cutting Fils. Here, a modern job cutting company is operating machine over a table sized 24,000 x 3,000 mm. The first their production facility. Small-sized locksmiths as gantry is equipped with a plasma rotator for bevel cut- well as large steel construction companies rely on the ting and two straight oxyfuel cutting heads for parallel products of MAP Prinzing Brennschneidtechnik GmbH. cutting of thicker materials. The drilling spindle enables Thanks to decades of experience, the contractor pro- drilling of holes up to 40 mm in diameter and tapping duces parts from small batches of 1 up to 500 pieces. up to M33. At the request of the company, a fully All this with innovative machines that make Prinzing automatic tool magazine for 16 tools has been added Brennschneidtechnik ready to handle even the most ur- to facilitate the wide range of jobs to be done on the gent orders. These are usually handled with a two-shift machine. operation and, if necessary, a third shift may be added on short notice. The second gantry also contains a drilling unit for drilling up to 40 mm, tapping up to M33 and counter- The most common tasks for this sheet metal service sinking. In addition, there are another three 2D oxyfuel include production of custom parts using plasma and cutting heads and a punch marker. “There were no oxyfuel cutting technologies. On average, 300 tons problems with the commissioning even though our of raw material are processed every month. Prinzing existing table was integrated together with our suction Brennschneidtechnik has recently invested into a system. We are satisfied with the performance, the drill- multi-functional cutting system which offers a multitude ing works great,” concludes Mr. Prinzing. of processing options. After an extensive search for the

Hans Prinzing Managing Director Prinzing Brennschneidtechnik GmbH & Co. KG

“The decisive factor for MicroStep was the bevel cutting head and the drilling unit. MicroStep‘s drill

The combined plasma and oxyfuel cutting solution at MAP was the most powerful among all competitors. We Prinzing Brennschneidtechnik GmbH enables bevel cutting with plasma, 2D oxyfuel cutting, drilling, tapping and marking are satisfied with the performance.“ on two gantries. At the request of the company, a tool magazine for 16 tools was added. 16 Additional beveling with oxyfuel The leading Spanish earthmoving equipment manufacturer Solintal “turns projects into reality”

Over 50 years ago, a small repair business called therm XPR300™ and an oxyfuel bevel cutting machine domes and beams as well as on a simpler design – the Talleres Alcobendas has been founded, specializing in CombiCut. Plasma bevel head – that was delivered with Solintal’s mouldboards, tiltrotators and other agricultural tools. Being a renowned innovator with more than 18 years of MasterCut. Apart from development of the heads´ me- Over time, the workshop continued to grow and be- experience in development of bevel cutting equipment, chanical design, great focus was also put on developing came Solintal, a leading company in design, manufac- MicroStep emerges as a supplier of choice for many methods for compensation of physical limitations of MEET THE TECHNOLOGY THAT REVOLUTIONIZES PLASMA. ture and supply of comprehensive solutions and tools when talking about bevel cutting. Since the introduction cutting technologies and processes to ensure higher for earthmoving and mining machinery as well as of its first rotary plasma bevel heads in the early 2000s, accuracy, enhance functionality and maintain long-term other industrial equipment. Recently, the company has customer-driven research and subsequent improve- stability. The results are advanced techniques such as invested in cutting-edge technology from MicroStep. ments of this technology led to a continuous increase Auto-calibration of Tool Geometry (ACTG®) for fast and in sales of MicroStep’s beveling tool stations. That, in easy calibration of geometry of the bevel tool, Adaptive Today, Solintal is known for its high degree of special- turn, brought the company invaluable experience with Bevel Compensation (ABC) for adjustment of bevel an- ization, excellent quality of its products and recognized long-term maintenance of these systems and related gles on cut parts or Self-teaching Height Control (STHC) aftersales services. With facilities covering over 16 000 issues. The knowledge obtained thanks to ever-growing for control of cutting height based on arc voltage for m2, the company has in recent years become known demands of its customers resulted in numerous en- variable bevels with plasma. Another great technology is for being a modern business with a philosophy based hancements of not only the mechanical design of bevel ABP – Additional Beveling Process for cutting bevels on on innovation, constant improvement of services and heads; it also contributed to overall stabilization of the already cut parts. personal approach towards its customers. bevel cutting process. Over the past few years the company has undergone a In 2018 MicroStep has launched the next generation of series of changes with the management starting a pro- The approach of overcoming drawbacks and limitations infinite rotator with several enhancements – one that is cess of overall modernization of the company. Although systematically resulted in solutions that are universal, especially attractive is the increase of the maximum tilt the manufacturing side was less affected by abrupt applicable to various cutting technologies and to angle to 65°. The latest innovation is integration of an changes since the production means and equipment various bevel head designs. Beveling with plasma has oxyfuel torch into the rotator – a technology that expos- were being continuously upgraded, the recent need for been gradually supplemented by other technologies es a whole new application area. enhancement of manufacturing capabilities resulted in – waterjet, oxyfuel and laser. Besides standard types a purchase of two machines from MicroStep: a plasma of bevel heads, MicroStep has also been working on Additional beveling with oxyfuel – just 45 minutes bevel cutting machine MasterCut with a work area of development of special rotary heads with pantographic instead of 6 hours for a part to be finished 12,000 x 3,000 mm with a 300 A plasma source Hyper- arms for cutting of 3D shapes such as pipes, profiles, Solintal was initially looking for a double- or triple-torch solution. For their jobs, e.g. 45° Y-bevels on parts 160 mm thick, oxyfuel was naturally the technology of choice. However, the geometry of a triple torch – especially the tangential offset between torches – imposes limitations on possibilities to cut different contour shapes. Distorted inner bevels and a rather significant waste of material when beveling thick materials are the most obvious drawbacks. At the time, MicroStep had the technology of the oxyfuel rotator almost developed, The XPR300® with X-Definition™ from and presented it to the customer. The proposal was accepted. Hypertherm represents the biggest advance Apart from the possibility to cut direct bevels with oxyfuel in a broad thickness range, the biggest innovation in mechanized cutting technology ever. This next is the use of ABP. A laser scanner scans the shape of a part which was previously cut with a straight oxyfuel generation system with expanded capabilities head and moved to a free place on the cutting table. Based on the part’s real shape and exact location, MicroStep’s ABP offers the possibility to add bevels and improved cut quality will show you plasma to the contours. Besides excellent cut quality, smooth surface and accurate contours, this technique saves a like you’ve never seen before. Learn more at great amount of material. Furthermore, the movement capabilities of a rotator enable cutting of a great variety hypertherm.com/XPR300. of contour shapes – as a consequence, for parts that For the jobs at Solintal (e.g. 45° Y-bevels on parts 160 mm previously took 6 hours to finish, Solintal now need just thick) oxyfuel was naturally the technology of choice. The 45 minutes. Another great advantage that ensures high movement capabilities of rotator allow to cut a great variety PLASMA | LASER | WATER JE T | AUTOMATION | SOF TWARE | CONSUMABLES output accuracy is the possibility of auto-calibration of of contour shapes. A high output accuracy is ensured by the oxyfuel rotator in exactly the same way as plasma or the possibility of auto-calibration of the oxyfuel rotator – laser – with MicroStep’s ACTG® technology. thanks to MicroStep‘s patented ACTG® technology. 19 Thanks to the mScan technology, the 3D scan of a dome enables to determine production-related deviations from the ideal contour that then could be compensated for accordingly during cutting.

Production of pressure vessels and boilers counts positions (based on the exact measurement of machine among the major industrial applications where cutting kinematics by a laser interferometer) as well as the of 3D objects comprises an essential part of the pro- calibration data of the bevel head and 3D scanner itself duction process. The obvious requirement is to make (obtained via MicroStep´s patented auto-calibration this process fast, simple to setup and, most impor- technology ACTG). tantly, with an accurate result that won´t need further mechanical or even manual processing. Typical cutting High quality results and big time savings by tasks in this regard are cutting of openings in a dished processing domes with many openings and welding end of a vessel for welding of inlet pipes, slicing of a preparations. dished end or trimming of the edges of a dished end with preparation for its welding to the vessel body. As a result, the control system has information about The cross-sections of the cut edges must meet the the exact position of the scanned object with respect to requirements of the subsequent welding process – in the cutting tool and thus enables exact scanning of this other words, depending on the wall thickness of the object within the coordinate system of the particular cut object, the V-, X- or K-cuts with constant or vari- cutting machine. The scanner then uses mScan to create able bevels need to be produced with the prescribed a detailed surface representation (3D model) of the accuracy, possibly in a fully automatic process. object from point cloud while fully describing its parameters including its deviations from ideal shape. For such tasks MicroStep has developed a special beveling tool station that enables tilting of tool up to 120° MicroStep´s 3D CAM software mCAM is then used to while having a big enough stroke to reach across the map the generated cutting path (meaning the ideal cut- whole dome surface. Furthermore, MicroStep has newly ting path created for the ideal shape of the object based introduced an advanced 3D laser scanning process and on its STEP model) onto the real scanned object. Sub- a corresponding point cloud mapping software – mScan sequently, a new cutting plan is generated to fit exactly – that enables a CNC cutting machine to measure the the true shape of the scanned object. All the described true shape of a 3D object, e.g. a dome, and use this automatic processes are conveniently displayed for the measurement for adjustment of the subsequent cutting operator in the form of 3D visualizations on the control process so that contours and openings are cut in the system screen. Depending on the dome size, this whole needed positions on the surface with a very high preci- process, which is carried out prior to the actual cutting, sion – compliant with the production requirement. takes from 2 to 10 minutes.

Needless to say, implementation of such 3D scanning Of course, there are cases where it isn´t necessary to technology greatly contributes to increasing of the perform the whole process and thus the time is signifi- Maximum precision in dome cutting is made possible by accuracy of the dome cutting process, as the real cantly decreased. In case the customer needs to mea- MicroStep‘s mScan technology. In the process, a laser scanner dimension of a dome can lay within – at least – allowed sure just the dimensions of dome, it is enough to scan a integrated into the portal determines the 3D surface geome- tolerances which in fact means that the real and ideal “cross” projected over the top of dome – this way, also try of the workpiece in advance. Dome shapes of domes sometimes differ by several centime- the exact position of the dome top is determined, which ters. Conventional methods of positioning corrections may be important for the next production steps. The top via control of plasma arc voltage are thus not applicable of dome can be marked with a marking head or directly in case of 3D cutting. Implementation of a scanner on with a plasma torch, depending on the particular config- the other hand makes it possible to create a model of uration of the machine. Also, if the cutting plan involves the actual dome surface within the coordinate system of just a part of the dome surface, e.g. the spherical top cutting the cutting machine and to subsequently use this model part that is usually quite flat, it is not necessary to scan to analyze the shape of the dome, identify its center and the whole dome extensively. In case of cutting into the define the exact toolpath above the surface. How does more flat top part the height control during cutting can it work? be based on plasma arc voltage which is a standard function of any MicroStep plasma cutting machine. During the scanning process, the iMSNC control sys- expert tem receives data from the scanner and pairs it with All processes and 3D scanning functions are handled by positions of all motion axes of the machine in each the machine operator or easily accessed via a company moment. The measured positions are further adjusted network. Additionally, mScan provides an analysis of by applying displacement corrections of particular axes shape geometry – a comparison of the true and ideal mScan: Unique technology sets shapes of the scanned object which in itself is a powerful tool for verification of production output in production of 3D objects, e.g. domes. standards in high-precision processing Thanks to the modular structure of MicroStep machines in terms of machine dimensions, types and locations Alexander Varga, Ph.D. of cutting zones and configurations of tool stations, a of dished ends for less rework Head of R&D particular machine can be designed according to exact MicroStep requirements of a customer´s production. A single gantry with a bevel tool station, 3D scanner and marker can be used for cutting of domes as well as flat sheets “With mScan technology, we can – an example is the DRM machine for Slawinski GmbH achieve unprecedented precision in Germany with a flat-bed cutting of sheets on the area of 14 x 6 m and dome cutting in the range of Ø 500 in dome cutting.“ – 5,500 mm with a dome height up to 1,200 mm (for further information please have a look to page 21). 21 EXTRA: MicroStep mCAM – CAM solution for cutting of 3D parts Modern industrial factories, which greatly focus on ef- 3D models and is able to process 2D and 3D formats Simulation and graphical visualization of CNC Processing time greatly reduced ficiency, automation and computerization of produc- commonly used in industrial production: programs tion processes, have been increasingly relying on CAD design software, which allows 3D modelling of parts • 3D CAD models – in STEP, IGES, DSTV, XML and IFC The software’s main output is a CNC code – a cutting and construction assemblies. The option of easy and • 2D shapes wrapped around/projected on parametri- program for a MicroStep cutting machine or, with the Brewing equipment specialists GEA accelerate their production comfortable 3D modelling has naturally also brought zed solid help of a post-processor, even for third-party machines. requests for CNC machines programming based on • Models created directly in mCAM using an integrat- The basic CNC code is standardized to DIN/ISO 66025 these models – 3D CAM software. ed modeler while also containing special control instructions for • existing CNC code (generated out of MicroStep’s various types of rotators and automation tools. mCAM with a combined plate and dome cutting machine MicroStep has been designing and producing complex SolidSel/PipeSel libraries) also contains a cutting simulator which enables visual cutting solutions for almost three decades. In addition inspection of the generated CNC programs. The simu- When it comes to the products of GEA Production to development of machines and their control systems, The software enables import of 3D assemblies where lator can display progress curves of machine and tool Kitzingen GmbH, the highest possible precision is a the company has also been focusing on development each assembly element is recognized as a separate movements in great detail, speed and performance fundamental requirement. That is what the customers part. Afterwards the parts are sorted according to their controls and dynamic kerf compensation. It shows the of its own software tools for creation of cutting plans: expect of the containers and equipment of the major the CAM software package AsperWin® for cutting of shapes, sizes and materials. The entire cutting plan workpiece that was defined before the program gener- food processing industry supplier. High quality pro- plates, which included also parametric libraries for preparation, from loading of the parts to adjustments ation, the cutting tool, all cutting paths and detection duction requires experience, precise work and modern creation of cutting plans for 3D shapes – pipes, profiles, and nesting consist only of a few easy steps. points on the surface as well as useful charts, which can domes and pipe elbows. Years of experience with 3D help reveal possible unwanted movements. machine solutions. Based on advice from MicroStep, cutting of various materials resulted in development of mCAM uses in-depth shape analysis for correct recog- the professionals decided to procure a plasma cutting another tool – a 3D CAM software launched under the nition of complex cuts and weld preparations (V-, Y-, machine of the MG series for 3D processing of sheets name mCAM. X-, K-cuts) that simplifies the subsequent work with and domes. The Head of Production in Kitzingen, parameters and properties of cutting paths, contours Eduard Sauter, considers this “a huge benefit. I recom- mCAM is designed for advanced 3D production with and individual parts. Complex features and function- mend MicroStep at our other sites that have a similar plasma, oxyfuel, waterjet and laser technologies. The alities (such as automatic detection of cutting paths, portfolio.” program can process 3D models created by common dynamic 3D compensation of kerf width according to CAD software and offers automatic nesting of parts the used tool, insertion of micro-joints, different lead-in The containers and appliances that GEA Production and automatic generation of CNC programs including and lead-out shapes and 2D/3D cutting simulation), Kitzingen builds for their customers are real giants, combined with an intuitive graphical interface, make visualizations and simulations. A straightforward manufactured with the highest precision and cut- user interface enables easy, efficient and accurate this program highly efficient and well organized. ting-edge technology. The products they make for the processing of parts, as well as easy implementation of processing industry can be up to 70 tons heavy, up to special technological operations (e.g. marking of text or A variety of supported part shapes contours, or drilling). The entire cutting process can be 13 meters in diameter and 17 meters in length. Very conveniently simulated in 3D, which allows the operator Shape recognition is based on detection of 3D surface high standards on surface roughness as well as high to check details of cutting paths, positioning of pipe geometry according to known geometrical parameters accuracies and tight tolerances are required so that the supports and to monitor the overall motion control on and properties of various supported shapes. The latest custom-made products may be installed and used as the contour – its speed, dynamic change of the kerf version supports detection of these 3D shapes: flat intended. width and machine movements in particular axes. plates, circular pipes and segments, hollow sections, elliptical, torispherical and semi-elliptical domes, cones, The international GEA Group is one of the largest pro- mCAM has been developed for easy generation of CNC arched, dished, flat and inverted domes, sphere-caps, viders of equipment for the food processing industry. programs for all types of cutting machines, with multi- extruded and bent U- and L-beams and H- and I-beams Kitzingen produces containers and equipment for food, ple options for cutting automation. The program uses with parallel and non-parallel flanges. pharmaceutical and chemical industries. “We make pos- boundary representation models in order to recognize sible what the customer wants,” says Eduard Sauter.

Accurate advice from MicroStep following a rigorous analysis of the production and portfolio

These customers are always demanding faster and faster delivery times by maintaining the same quality standards. In order to achieve this, the GEA Group is always on the lookout for new technology that offers process reliability and, if possible, has some added value in terms of quality and production speed. For these reasons, 2015 was the time to replace their plasma cutting Recirculate cleaned air into machine. Mr. Sauter preferred a laser cutting machine the work space but also gave plasma technology another chance. Mi- The ZPF series croStep took a close look at their production times and the production itself. “We had the MicroStep specialists www.teka.eu Power is variable – up to visit the production and evaluate which technology The perfect solution for almost would bring the most benefits.” 55 kW power is possible any air extraction requirement! And so, the decision was made to go with the all-rounder of the MG series supporting 3D cutting of plates and Set up several ZPF modules in a domes. A comparable laser solution wasn’t available on row to enlarge the filter area the market and the advantages of MicroStep‘s plasma rotator and the ability to trim bottoms of domes with bevels were the main decision factors. The plasma Optional spark preseparator technology fits perfectly with the requirements. GEA GEA Production Kitzingen opted for a multi-functional MG The typical processing time for a complex container bottom to eliminate risk of ignition produces small series of products and mainly cuts machine that allows to process metal sheets as well as dished with many connection parts (as an example see photo above) materials with thicknesses between 3 and 15 mm but in ends. was about one and a half weeks – today, if required, GEA can exceptional cases has to cut through 90 mm. produce within one day. Noise reduction with textile The machine has been operating in production since outlet June 2017. It processes plates on a working area 12,000 Eduard Sauter x 3,500 mm large and domes up to 3,500 mm in diame- Head of Production ter. The experience the company‘s specialist has had so GEA Production Kitzingen GmbH far is positive: “The way the machine works gives me an impression that it is rock solid. I recommend MicroStep at our other GEA facilities which have similar product portfolio.” “The machine is a great benefit. I Above all stands out the innovative mScan software from MictoStep designed for processing of domes recommend MicroStep at our other and other 3D objects. Now, the company with seat in GEA facilities which have a similar Franconia, Germany has no problem to keep up with the required tolerances. Additionally, a lot of the hard, man- product portfolio.“ ual work that had to be done by people before, such as cutting of the dome bottoms, welding edge preparation Cooperative project of TEKA and Microstep etc., is now done by the machine. at Slawinski & Co. GmbH in Siegen/Germany: Production of oversized container bottoms 23 +49 28 63 92 82 0 [email protected] www.teka.eu Substantial time saving New system replaces two machines The Hungarian pressure vessels manufacturer Faddikorr Domes from Slawinski are in demand all over Europe – the benefits from state-of-the-art dome cutting process company uses MicroStep’s technology to cut them

When designing the plasma cutting machine, the focus was on the precise and flexible processing of domes. A special dome cutting table supports domes from 500 mm up to 5,500 mm in diameter.

As a specialist for container bottoms and specialized flexible and precise processing of metal plates and pressure-vessel parts, Slawinski & Co. GmbH has been domes with exceptional dimensions. The DRM series, providing tailor-made solutions for a wide variety of a multi-functional plasma cutting machine for the customers for more than 100 years. The products of toughest jobs, has been expanded to include custom the family-owned company are used by small enter- technologies for the container bottom specialist. A Located in the far south of Hungary, Faddikorr has been mm, and a sturdy 3D plasma cutter DRM equipped with a prises and global corporations alike. Slawinski relies special dome cutting table can process domes from 500 manufacturing top quality stainless steel tanks, pressure pantographic plasma rotator capable of tilting up to 120˚ on state-of-the-art machine solutions. The company mm to 5,500 mm in diameter The pantograph plasma vessels and other equipment for food industry for more and with a Z-axis stroke of 1,500 mm, designed solely for counts on a MicroStep plasma cutting machine with rotator, with a tilt up to 120°, enables weld edge prepa- than 20 years now. In the beginning, there were only 4 cutting of domes up to Ø 3,500 mm. The integrated 3D an extraordinary configuration for 2D and 3D cutting ration also on the bottom edge of a dome. Plate cutting people, but today “The Faddi Family” consists of more scanner scans the dome’s surface to adjust the cutting to process their plates and domes. is possible with the same gantry on a work area of than 90 highly qualified and committed employees. program according to real dome dimensions. 14,000 x 6,000 mm, replacing the original plate cutting The laser scanner can reach the entire dome surface. The What gives Faddikorr the edge over its competitors is Flexibility, innovation and the highest standards are machine. measured data are compared with the ideal dimensions on the ability to meet all the special requirements of their In other words, local deformations of dome surface or an in demand when customers ask for solutions from which the cutting plan is based and deviations are automati- clients while still attaining the highest quality possible. incorrectly placed, tilted dome are no longer a problem. Slawinski & Co. GmbH from Siegen in the north west New standard for precision of contours and bevels on cally compensated for during the cutting process. Advanced cutting requirements such as various welding of Germany. The tailor-made container bottoms and domes When it comes to pressure vessels, the most difficult and preparations – V-, A-, Y-, X- or K-cuts –are easy to handle specialized pressure-vessel parts are known to manu- tedious task has always been tank ends and their ma- thanks to the machine’s flexibility, its user-friendly inter- facturers of pressure vessels and containers throughout A brand new feature on the Slawinski machine was the chining. Cutting all the required openings into a tank end face and the easy way of working with 3D solid models in Europe and beyond because of their quality. The fourth mScan technology for measuring of the true surface Faddikorr opted for two CNC cutting machines from Mi- used to take a very long time, between half and one and MicroStep’s 3D CAM software mCAM. For simpler tasks, generation of the approximately 130 employees use shape of a particular dome. Following a 3D laser croStep: fiber laser machine MSF with a straight tool station, a half day depending on the number and sizes of holes like pipe-dome intersections, the machine also offers their experience and state-of-the-art technology to scanning process to scan the dome entirely, advanced with work area 6,000 x 2,000 mm (below), and a sturdy 3D necessary for the specific pressure vessel. The purchase of simple macros with functionalities like welding prepa- create customized products. The range of end products algorithms are used to adjust the movement of cutting plasma cutter DRM equipped with a pantographic plasma a CNC plasma cutting machine from MicroStep has been ration generation or marking generation. The accuracy is large, each one a unique piece. Circles are cut out of tool according to the real shape of a dome and com- rotator capable of tilting up to 120˚ designed solely for cut- a radical change in this matter. Cutting, which used to and long-term stability of 3D cutting is achieved thanks metal plates and, after dishing, flanging, spinning, edge- pensate so for the measured deviations from its ideal ting of domes up to Ø 3,500 mm (on top). take a few skilled workers a day, now takes one hour and to MicroStep’s ACTG® system (Auto-calibration of tool and surface-processing, turned into container heads shape. “Based on our ABP technology, we developed all the work can be done by a single machine operator. geometry), which is able to calibrate the entire system and bottoms, arched floors and much more. “We supply the mScan technology specifically for dome processing This was the main reason for purchase of the plasma within 5 minutes, making the former man-assisted, hours- important components for construction of pressure and our engineers and programmers adapted it to the dome cutting machine according to the owner of Fad- long, manual geometry setup process basically obsolete. vessels for power plants, tanks for chemical industry and needs of Slawinski. This technology sets new standards dikorr, Mr. János Faddi: “We decided to buy the machine high-pressure containers. There, the quality has to fit for precision of contours and bevels cut on domes,“ says in order to reduce the cost of human labor. The drawing “We produce our own conical tank ends out of sheet exactly,” explains technical director Rainer Jurreit. MicroStep‘s co-founder and Head of Research & Devel- and cutting of a tank end used to take sometimes more metal. The best way to cut openings in these is to do it opment Alexander Varga, Ph.D. than a day. Thanks to the new machine, this time has before the sheets are bent into the cone shape. However, Demand for openings in domes could not be met to been significantly reduced.” many times we do not know where the holes are going to satisfaction Konstantin Slawinski is very satisfied with the solution: “Cutting of both plates and domes is the optimal The pantograph plasma rotator with a tilt up to 120° enables be until the very last moment. Our MicroStep DRM dome weld edge preparation also on the bottom edge of a dome. With high quality in mind, Faddikorr opted for two CNC cutting machine gives us the option to cut the openings Despite the high quality of production, company‘s spe- solution for our limited space. This system replaces two cutters from MicroStep: a fiber laser machine MSF with into already formed tank ends, making our work much cialists were looking for new and better ways of meeting machines.“ a straight tool station with a work area of 6,000 x 2,000 easier.” the transforming demands of customers. “Demands for openings in domes have been growing and we have not been able to satisfy it,“ says managing director Konstantin Slawinski. “We‘ve been searching for 10 János Faddi years, looking at many manufacturers and technologies, Konstantin Slawinski Owner, General Manager including robots. However, due to the dimensions of the Managing Director Faddikorr Kft domes, they could not meet our vision,“ says Konstantin Slawinski & Co. GmbH Slawinski. After all, the company produces domes with diameters of up to 5,400 mm.

At EuroBlech 2014 in Hanover, the company came across MicroStep. “There, we were looking for a machine for dome cutting, we wanted to cut radial holes. With “The DRM plasma cutter from our machine, we could not cut what we envisioned. “For the first time in our ten-year search, That‘s when we noticed MicroStep, which we did not MicroStep gives us the option to cut even know before,“ says Alexander Fries, Head of Pro- we had a feeling that there is someone openings into already formed tank ends, duction Planning responsible for preliminary selection who wants to sell something they of technology. Managing Director Konstantin Slawinski making our work much easier.” adds: “We have seen that it works. For the first time in actually master.“ our ten-year search we had a feeling that there is someone who wants to sell something they actually master.“

MicroStep has developed an innovative system for 24 25 For cutting of open profile sections, such as I, H, U or L profiles, MicroStep introduced a concept with a 3D kinematic system that is positioning the cutting torch above the surface of a steady profile – this machine line is supplied under the name ProfileCut. During the cutting process, the cut profile is motionless while a specialized 3D cutting head with tilting ability of 120° moves around the profile both in the longitudinal and transverse directions.

Possibility to equipe ProfileCut machines with cutting zones for hollow profiles or sheet metal

Furthermore, the abilities of ProfileCut can be enhanced by adding a drilling/tapping/countersinking tool station with automatic tool exchange for plate drilling up to Ø 40 mm or by various marking tool stations. The precision of cutting and positioning of the tool above the actual profile is achieved by an advanced system of 3D scanning of profile shape with laser line scanner, followed by automatic adjustment of cutting program as well as adjustment of machine movements according to the true shape of material.

In addition to cutting of open profiles, ProfileCut machines can be equipped also with other cutting zones, e.g. for processing of hollow profiles (cutting by means of a pipe positioner like on a PipeCut machine) or a cutting table for sheet cutting like on a standard flat-bed machine – all by using the same gantry and tool stations. This concept makes the ProfileCut one of the most versatile cutting solutions for steel constructions on the market. For requirements of automation of the cutting process with automatic loading and unloading of material – no matter if sheets, hollow sections or open profiles – Micro- Step offers enhanced versions of its machines with input and output conveyors in which the material is inserted into the working area on a roller track by special gripper arms.

Such automated lines equipped with automatic measurement of the 3D solutions for thickness and dimensions of material offer further possibilities of automation in interconnection with information MicroStep has developed a variety of solutions for high-precision 3D processing of tubes, profiles and beams – including fully automated systems or production material handling. management applica- steel constructions tions like MicroStep´s MPM. Versatile options for beam and pipe processing: Automatic cutting machines for structural steel jobs “We no longer need to outsource” Bevel cutting of beams, pipes and plates: Innergy Heavy

Apart from standard flat-bed machines, MicroStep For cutting of hollow structures of circular and rect- Industries chose versatility and reliable service offers an exceptional variety of equipment for process- angular cross-sections MicroStep supplies the cutting ing of 3D rotary objects and structural steel sections of machines PipeCut and CPCut. various shapes. The rotary objects include differently INNERGY is a multinational company specializing in sized circular, square and rectangular hollow sections Both systems are of a modular execution, which means eco-friendly energy solutions thinking not only about (diameters of circular sections reach from Ø 30 mm up that they are configured for particular requirements of the needs of the customer, but also about the needs to Ø 2,000 mm), conical pipes, torispherical or ellipti- customer‘s production. of our planet. When it was founded 50 years ago, the cal domes and elbows. company has specialized in design and manufacture of PipeCut machines can have a working length of 3 m, 6 thermal oil boilers. However, over the time the world has changed and Innergy had to change with it. Today, Standard configuration of a MicroStep machine in sheet m or 12 m and can process pipes with diameter ranges its portfolio contains biomass generation and cogene- and pipe cutting execution consists of a cutting table Ø 50 mm to Ø 800 mm. The maximum wall thickness is ration plants, boilers or systems for use of residual heat. for sheets and an extracted channel for pipe positioning 50 mm for plasma cutting and up to 100 mm for oxyfu- that is placed along the longitudinal side of table. el. CPCut machines can process also large-sized pipes Today the company has three separate divisions (Innergy with diameters of up to Ø 2,000 mm. Heavy Industries, Innergy Electric and Innergy Engineer- Pipes are clamped in a rotary pipe cutting device ing), three international headquarters (Spain, Chile and located at one end of the channel. The cutting process Japan) and has worked on more than 6,500 projects on 5 involves a combination of movements: the gantry with continents. tool stations – straight or bevel – and the pipe cutting device are synchronized for a precise positioning of the Innergy opted for ProfileCut from MicroStep with work- pipe towards the cutting tool. In addition, special adapt- ing area of 12 x 4.5 meters for cutting of flat metal sheets. ers for clamping of polygonal profiles or elbows can be The machine is equipped with a pipe positioner and sup- attached to pipe cutting device. For cutting of domes, a Alexander Varga, Ph.D. porting rollers for cutting of pipes with diameter up to dome cutting area can be located behind or in front of Head of R&D 700 mm and profile cutting zone for cutting of H, U and MicroStep the cutting table. A single cutting tool is used to process L profiles up to 12 m long and 600 mm wide. The pan- all different shapes of material. tograph rotator is capable of tilting up to +/- 90° which makes the profile cutting feasible. All this supported by For applications in the structural steel industry Micro- “Our portfolio includes multi- the XPR300® plasma source from Hypertherm. Mr. David gy follows strict rules since we need equipment which How has the machine helped your manufacturing process? Step developed a product line of specialized machines functional systems that can Moldes, Chief Strategy and Corporate Development meets high quality standards characteristic for our com- for cutting of structural steel sections as well as sin- Officer, shared the decision making insights in a short pany. We aim to continue providing our customers with David Moldes: “Having the machine has helped us main- gle-purpose machines for automated cutting and drill- process sheet metal, tubes and interview: state-of-the-art industrial boilers and other products ly in two areas. First of all, by reducing manufacturing ing of flanged parts. These machines can be supplied and with this in mind, we decided for ProfileCut from times and at the same time by improving the quality of The calibration system ACTG® enables durable high-precision in various executions depending on types and sizes of beams as well as single pipe or Since 2017 you use a sheet and pipe cutting machine. Why MicroStep. During the selection process we didn’t only our heater products. In addition, thanks to the results – also with the pantograph. This specialized 3D cutting processed material or the requirements for automation did you decide for ProfileCut from MicroStep? take the machine’s features into account. The important incorporation of ProfileCut we no longer have to out- head with tilting ability of 120° moves around the profile both of material input and/or part output, and alternatively profile processing solutions.“ factor was also the good references MicroStep has on source the parts cutting. That gives us both speed in the longitudinal and transverse directions. connected to a production line in the customer´s facility. David Moldes: “Acquisition of new equipment in Inner- the market.” and self-sufficiency.” 26 27 “The machine runs very well“ Market leader trusts MicroStep The French company Mecasem relies on MicroStep’s Pipe cutting machine for the Chinese Gree Group: the world’s technology for sheet and pipe processing largest manufacturer of air conditioning solutions

The Mecasem Group is primarily focused on precision When it comes to air conditioning, Gree Electric in material testing and measuring equipment cali- Appliances Inc. is the world’s number one. In their bration. However, one branch of the company is also production, the company relies on machinery from an engineering company supplying heating and air MicroStep. conditioning products. In order to increase speed and flexibility in its production, the company invested in The HQ of Gree is located in the vibrant city of Zhuhai; a special plate and pipe cutting machine from Micro- here the company develops and manufactures air con- Step. The decisive factor that prompted Mecasem to ditioning units with a turnover of more than 13 billion approach the leader in automated plasma cutting was euros per year. Air conditioning solutions from Gree find MicroStep‘s innovative technology. their application in many housing and industrial facilities worldwide, from single family homes up to large presti- On the German-French border, in the midst of romantic gious projects such as the site of the final match of the vineyard landscapes, lies the city of Ostwald. This is the 2010 Football World Cup, the National Stadium in South place where Mecasem Group offers its services. Found- Africa (Soccer City) in Johannesburg. Projects like these ed in 1980, the group is a leading industrial laboratory require a high degree of precision when manufacturing specializing in materials testing and gauge calibration. components. Big construction projects in particular re- At its HQs, Mecasem also produces components for quire very long pipes to be cut with utmost accuracy. heating and air-conditioning technology. “For example, we manufacture pressure vessels and oil separators for In 2016, Gree went on to look for a cutting solution that customers in France,” explains the production manager would suit their needs. During the search, the company Pierre Ruble. The company operates eight branches in ables bevel cutting up to 50° on both plates and pipes. Mecasem was able to handle in-house orders in a focused on a CNC system for long pipes that would offer France and one in Germany. “We used to buy pipes from a supplier. The problem flexible and fast fashion, Mr. Ruble and Mecasem‘s CEO the possibility of cutting holes with bevels on the edges was that it was very inflexible – deliveries took too long,” Marc Meyer were intensely searching the market. “We in preparation for the subsequent welding processes. In June 2014, an extraordinary machine went into says Pierre Ruble. have received four offers including a robotic system,” Within the same year, the decision fell on a PipeCut operation, MicroStep‘s CNC plasma cutter CombiCut says Pierre Ruble, looking back. After weighing all machine from MicroStep configured for cutting pipes 12001.15Prk + CH2000P. The system, designed for ro- The new machine is in operation at least eight hours per parameters, the choice was made to go for the world with the maximum length of 12 meters and maximum bust and multi-functional use as well as parallel cutting, day with two operators taking turns. Around 4,000 pipes market leader in automated plasma cutting. “We were diameter of 610 mm. The machine is equipped with has been tailored to the needs of the company while were cut during the first year. “There’s probably going convinced by the combined pipe and plate cutting MicroStep‘s industry-proven plasma rotator that enables integrating also components from another MicroStep to be more. But we will still have some capacity left,” machine. Others had that too but we liked MicroStep easy and precise bevel cutting of pipes up to 45° with machine series – the pipe & beam cutting machine Pro- emphasizes the production manager. 90 to 95 percent the most.“ Feelings after more than a year of operation edge preparation for welding. Furthermore, in accor- fileCut. Thanks to this crossover, the machine does not of the pipes and sheet metal processed by the machine are still very positive. “Support from MicroStep is good dance with Gree‘s requirement for a combined machine only process plates within the work area of cutting table are from mild steel and a small percentage is stainless and fast. We are satisfied with the machine, it is running that could process pipes as well as domes, the design 3,000 x 1,500 mm, but is also able to handle big pipes steel. very well.” of the machine for the air conditioning expert has been Top left + right: Gree‘s combined pipe & dome cutting machine PipeCut allows to cut pipes up to Ø 610 mm and a length of 12 up to Ø 1,000 mm and 12 m long with automatic pipe tailored to include a 1,400 x 1,400 mm large cutting table m as well as domes up to Ø 1,200 mm. Bottom left: Gree Electric Appliances Inc. was chosen to participate on prestigious projects clamping. MicroStep‘s plasma rotator ACTG® feature en- Before the new machine was put into operation and for 3D processing of dished ends. such as the National Stadium (Soccer City) in South Africa‘s Johannesburg.

Visit KMT Waterjet Systems in Hanover 23–26 October 2018 | Stand H163 Hall 12

BENEFIT FROM THE EXPERTS IN WATERJET CUTTING DISCOVER OUR LATEST PRODUCTS FOR POWERING YOUR WATERJET CUTTING SYSTEM

STREAMLINE PRO for worldwide fastest Waterjet TRILINE 30 Direct-Drive Pump offering excellent Cutting at up to 6,200 bar cost of ownership value

■ Cutting at 6,200 bar offers a considerable ■ Comparably simple technical design featuring small increase of cutting speed while decreasing the footprint and high efficiency consumption of abrasive per part ■ Ideal for continuous operation ■ Improved intensifier design including the patented SUPRAlife Ultra High Pressure Seal enables significantly increased productivity

High Pressure Technology for Waterjet Cutting by www.kmt-waterjet.com T +49 (0) 6032 9970 | [email protected] EXTRA: Overview of MicroStep’s laser product series

The compact basic version – MSF Compact – is delivered in three standard sizes with work areas of 1 x 2 m, 1.25 x 2.5 m and 1.5 x 3 m. Designed as a plug-and-play solution for smaller workshops.

MicroStep´s high-precision all-rounder MSF can be delivered in various sizes from 3 x 1.5 m to 12 x 3 m. MSF machines can have cutting heads for straight or bevel cutting, with a maximum bevel angle 45°. Optionally, MSF machines can be enhanced with supplementary zones for cutting of round tubes and hollow profiles of different cross-sections.

The flagship seriesMSF Max can be delivered up to an overall table dimension 50 x 6 m. This powerful machine is with The flexible beam guide of a fiber laser system not only allows fixed cutting table and a moveable cabin building large-scale machines several tens of meters long, that covers the active cutting zone. it also allows a much simpler construction of bevel cutting Cutting of part up to a length of 20 m is heads, easier integration of additional technologies such as possible. drilling, tapping, marking, additional beveling (ABP) as well as addition of equipment for cutting of pipes and profiles.

The fiber laser experience MMI consoles with 4 24“ touch screens plate cutting area 1 MSF product line offers multi-functionality and versatility 1 4

Thanks to the use of optical fiber for laser beam trans- all-rounder MSF – can be delivered in various sizes from 3 plementary zones for cutting of round tubes and hollow automatic pipe mission, great possibilities emerge in the field of laser x 1.5 m to 12 x 3 m. It is equipped with an automatic shut- profiles of different cross-sections. There are several cutting area 3 cutting. The flexible beam guide not only allows build- tle table with two cutting grates that enable simultane- options: pipes up to Ø 200 mm, Ø 300 mm (in special automatic ing large-scale machines several tens of meters long, it ous operations of cutting and loading/unloading. Waste cases even up to Ø 500 mm) and hollow sections with the 2 shuttle table also allows a much simpler construction of bevel cutting collection and disposal is facilitated by a belt conveyor same values as circumscribing circles respectively. Pipe heads, easier integration of additional technologies and a waste container integrated in the cutting table. The cutting zone of MSF is placed inside the cabin along the such as drilling, tapping, marking, additional beveling machines are equipped by default with automatic lubrica- X axis while material handling is conveniently ensured by output container for 2 5 (ABP) as well as addition of equipment for cutting of tion system that shortens and simplifies their maintenance a sliding side panel of the safety cabin. In addition to pipe large pipe products pipes and profiles. Solid-state fiber lasers have paved process. cutting with manual loading, MSF can be also equipped the way towards installation of multi-functional CNC with a fully automatic pipe cutting system that allows cutting centers similar to those already widely used in Control of cutting height is provided by a capacitive cutting of pipes and hollow profiles up to Ø 200 mm, with the plasma field. sensor inside the cutting head a transversal loading conveyor on the input, automatic 6 feeding of the pipes into the cutting area by a moveable 5 output onveryor for small pipe products Over the last decade MicroStep gradually developed its MSF machines can have cutting heads for straight or chuck, and a transversal output conveyor for small parts automated pipe fiber laser product line as a modular design that allows bevel cutting, with a maximum bevel angle 45°. Control as well as a collecting tray for bigger parts on the output. loading 3 6 creation of customized systems, reaching from simple ma- of cutting height is in both cases provided by a capac- The pipe cutting function is offered as well as a stand- chines to complex cutting centers with different work area itive sensor inside the cutting head that automatically alone pipe cutting machine MSF Pipe, both in manual and sizes and possibilities of material flow automation. The measures the distance between the cutting tool and cut automatic configurations. aim is to deliver machines that meet particular production material. For proper function of the measuring system, it requirements of a variety of end users. Equipped with is necessary to keep the cutting nozzle undamaged and For large-scale cutting tasks MicroStep launched the EXTRA: Bevel cutting and processing of tubes and profiles state-of-the-art laser sources and cutting heads, efficient clean: for this purpose, a combined LU3K station is inte- flagship series MSF Max fume extraction and safety cabins that prevent exposure grated in the beginning of cutting table. Besides optical MSF machines can have cutting heads for straight or bevel cutting, with a maximum to laser radiation, these machines are delivered as turnkey check of the nozzle status by a built-in camera, the station For large-scale cutting tasks MicroStep recently launched bevel angle 45°. Optionally, the machines can be enhanced with supplementary solutions with a variety of functions. also automates the processes of nozzle cleaning and the flagship series MSF Max that can be delivered up zones for cutting of round tubes and hollow profiles of different cross-sections. calibration of the capacitive height sensor. Additionally, to an overall table dimension 50 x 6 m. This powerful Plug & Produce: The compact design allows easy trans- for bevel cutting heads the calibration is carried out auto- machine is with fixed cutting table and a moveable cabin port and quick set-up matically for the whole range of tilt angles. that covers the active cutting zone. Cutting of part up to a length of 20 m is possible. This machine allows for one The compact basic version – MSF Compact – is delivered The laser bevel head comes with the industry-leading or two beveling tool stations, drilling tool station with in three standard sizes with work areas of 1 x 2 m, 1.25 auto-calibration system ACTG automatic tool exchange (up to Ø 30 mm). Above left: The laser bevel head comes with x 2.5 m and 1.5 x 3 m. Designed as a plug-and-play the auto-calibration system ACTG, ensuring that solution for smaller workshops, MSF Compact machines Same like for other beveling technologies from MicroStep, The modular design of MSF product line provides a wide potential mechanical inaccuracies will be com- are equipped with laser sources up to 4kW and a single also the laser bevel head comes with the industry-leading range of configuration options. Customers get the possi- pensated by counter-movements of the machine. cutting grate that is pulled out to the front of the cabin for auto-calibration system ACTG, ensuring that potential bility to configure their laser system exactly according to convenient loading of workpieces and unloading of cut mechanical inaccuracies which may occur in the me- their needs and to integrate it most effectively into their Above right: The machine version MSF Pipe is parts – with a maximum load of material up to thickness chanical setup of bevel head during long-term use will production workflow. Thanks to the modularity, various designed exclusively for processing of pipes and 15 mm. The compact design allows easy transport and be accurately compensated by counter-movements of levels of automation of material flow are possible – an rectangular profiles. quick set-up that makes the machine an ideal solution the machine. ACTG greatly contributes to the long-term automatic loading system for sheet metal MSLoad, a stor- for accurate and reliable 2D cutting of parts with fine stability and efficiency of bevel cutting process. age tower or an automatic cut part sorting system MSSort Left: The automatic sheet loading system MSload, contours and detailed cut-outs. being the valued options. a storage tower or the part sorting system MSSort The standard version – MicroStep´s high-precision Optionally, MSF machines can be enhanced with sup- are valued options for the MSF series. 30 31 Successful launch of MSF Max at the traditional French cruise ship builder Laser flagship with bevel cutting solution debuted with style in Chantiers de l’Atlantique

Chantiers de l’Atlantique shipyards (until recently STX are building the world’s largest cruise ship you will most higher and the optical fiber that guides the laser beam Above: Chantiers de l’Atlantique opted to invest into a France), located on the coast of the Atlantic, have had likely need big parts, which need to be cut out with is not limited by length and requires almost no mainte- large-scale fiber laser cutter MSF Max. It is a 50 m long a long tradition in cruise ship construction, many of great accuracy, and you have to cut a whole lot of them. nance. “An easy-to-use-and-maintain concept was an machine with two 21,000 x 3,500 mm cutting zones. them being the largest at their time. More recently the “We cut about 1,600 meters of material every day,” says important criterion in our decision process.” company has expanded its focus also to the offshore Project Manager Silvère Destrem. The machine is equipped with a 3D bevel cutting head Left: Accuracy and long-term stability of the machine is renewable energy constructions. After some consideration, Chantiers de l’Atlantique with an 8 kW laser source that allows Chantiers de ensured by MicroStep‘s patented auto-calibration system opted to invest into a large-scale fiber laser cutter, the l’Atlantique to make weld edge preparation on parts (ACTG®). The ACTG station has been integrated together Up to 150 years ago, Saint-Nazaire was just a simple MSF Max. It is a 50 m long machine with two 21,000 x up to 20 meters long and up to 16 mm thick with bevel with a calibration pad for the capacitive height sensor and harbor village on shore of the Atlantic Ocean. Its 3,500 mm large cutting zones. The work area consists of angles ranging up to 45°. The system is easy to use a nozzle cleaning system in a combined technological strategic location near the mouth of the river Loire has suction tables sunk into the ground of the production and maintain: accuracy and long-term stability of the station that is placed under the gantry and ejected in case proven vital with the arrival of the industrial revolution. hall to allow easy access onto the grates during loading machine’s geometry that is essential for accurate bevel of calibration. In 1861 John Scott from the Scottish shipyard in Gree- and unloading. The suction table is divided into elec- cutting is ensured by MicroStep´s patented auto-calibra- nock has been appointed to establish a new shipyard tronically controlled zones with pneumatical opening tion system ACTG®. All the operator needs to do is to Below: Just this year in March, Symphony of the Seas, and to supervise the construction of the very first ship of flaps that ensure high suction efficiency and allow swap the cutting nozzle with a calibration jig and initiate the largest cruise ship ever built, has left the port of Saint- Impératrice Eugénie, which was delivered only three customized setting of zone opening times. the automatic calibration process – if any inaccuracies Nazaire for its maiden voyage. years later in 1864. are detected, the machine will automatically adjust its Since then, shipyards in Saint-Nazaire have been “The idea was to improve our workshop with a mod- movements to compensate for the measured mechani- undertaking colossal projects that often require the ern and efficient machine” cal deviations. latest achievements of science in order to be feasible.

With this context it is no surprise that, over the years, The older CNC laser machine at the shipyard was a CO2 After a few months in production the feelings are this small French town has become the birthplace of type. Even though CO2 lasers have certain advantages, positive. some of the largest ships of their times. Just this year such as the ability to cut different materials and deliver in March, Symphony of the Seas, the largest cruise smoother cut surface especially in bigger thicknesses, Because of the large machine size in this particular case, ship ever built, has left the port of Saint-Nazaire for its they are less efficient and require regular maintenance the ACTG calibration station is placed in a combined maiden voyage. of the laser beam path, with the setup and alignment technological station that is mounted directly on the Today the shipyards have more than 2,700 employees of the mirrors in the beam path limiting the maximum gantry and is ejected during the calibration process. The and more than 500 subcontractors bringing another length of the machine setup. For larger-scale applica- station also contains other equipment – a pad for cali-

5,000 workers on the site every day. tions, the CO2 laser source needs to travel with the gan- bration of the capacitive height sensor inside the laser Working in a shipyard can be a very de- try while maintaining beam path geometry at a required head, as well as a nozzle cleaning system consisting of manding and exhausting job, even precision. That brings several design and production a camera and a wiping brush. In addition, high absolute for a soulless machine without hu- challenges – the more complicated the system, the accuracy of the machine (approx. 0.2 mm at room tem- man needs and cravings. If you more demanding it is in terms of maintenance and the perature) has been ensured by a positioning tolerance higher is the probability of downtimes. “The idea was to compensation feature, based on precise initial machine improve our workshop with a modern and efficient measurement with a laser tracker device. machine,” explains Mr. Destrem. Fiber laser After a few months in production the feelings are pos- technology eliminates several of itive. “The quality of the cut pieces is better than with

CO2’s setbacks. our old machine. The efficiency has increased. We have Its efficiency is the opportunity to make the production evolve towards much new products,” concludes Mr. Destrem.

The machine is equipped with a bevel cutting head with 8 kW laser source that allows Chantiers de l’At- lantique to make weld edge preparation on parts up to 20 m long with thicknesses up to 16 mm and bevel angles up to 45°.

“The quality of the cut pieces MSF Max is better than with our old Video presentation: machine. The efficiency has increased. We have the opportunity to make the

Silvère Destrem production evolve to new Project Manager products.” www.microstep.eu/video Chantiers de l’Atlantique

32 Irving gears up with MicroStep Shipyard invested in a 16 m wide gantry with bevel technology

Irving Shipbuilding Inc. (ISI) has built one of the most powerful combinations of shipbuilding, ship repair and fabrication expertise in Canada and the eastern seaboard of North America in more than fifty years. The company has built over 80 % of Canada’s current fleet, and its Halifax Shipyard has been at the forefront of Canadian shipbuilding for more than 125 years. Today, the company also relies on technology from MicroStep.

ISI consists nowadays of five shipbuilding, repair and fabrication facilities – all committed to the company values of integrity, customer service and pride. Together, they make up Eastern Canada’s most extensive array of docks, slipways, steel fabrication shops, outfit and machine shops and blasting and painting facilities. CNC cutting systems for In 2011, the historic National Shipbuilding Procure- ment Strategy (NSPS) was undertaken by the Canadian Government, seeking to identify two shipbuilding Centers of Excellence for the country for the next 30 years. Irving Shipbuilding was extremely proud to have large-scale applications been selected by the Canadian Government to build the Royal Canadian Navy’s new combat fleet, a program that comprises 21 vessels and $25 billion over a period MicroStep partners with global welding automation expert of 30 years. Canada’s chosen shipbuilder As Canada’s chosen shipbuilder, Irving Shipbuilding Inc. is As Canada’s chosen shipbuilder, Irving Shipbuilding working with the Royal Canadian Navy. Pemamek for advanced shipyard projects Inc. is working with the Royal Canadian Navy on the next class of Canadian Surface Combatant (CSC) and As a manufacturer known for innovations and custom- in shipbuilding is production of large-scale panels Advanced features for precise panel processing Arctic and Offshore Patrol Ship (AOPS) vessels under er-driven R&D projects, MicroStep has a rich history with welded stiffening structures that are used to build the National Shipbuilding Strategy (NSS). The long- One part of this giant investment included the purchase wide gantry is equipped with a plasma rotator for CNC of supplying the shipbuilding and offshore industries decks and bulkheads of a ship. In modern shipyards, Panel cutting machines need to have several special term promise of stability granted by the NSS led the of a cutting-edge panel line from the Finnish global bevel cutting up to 50° and with additional heads for with emerging cutting-edge technologies. Over almost these panels are produced by used fully automated and features. For example, the starting point of cutting has shipbuilder to invest in its Halifax Shipyard to build welding and production automation provider Pemamek sandblasting (primer removal), plasma marking and two decades the company has supplied numerous robotized high-tech flat panel lines consisting of several to be set in relation to the position of welds on the pan- North America’s most modern and largest specialized Oy. MicroStep has been a part of this project and sup- inkjet marking. machines to well-established names in the industry gantries that provide the technologies for welding of el since the finished product has exactly defined weld shipbuilding facility. plied the plasma cutting part of the line: the 16-meter such as STX, Damen, Vard/Fincantieri, Royal IHC, single sheets to make a panel and subsequent cutting positions. Therefore, the machines are equipped with a Lürssen, Meyer, Keppel and many more, a majority of and marking processes, positioning and welding of linear laser scanner to identify of welds in any direction. which were combined plasma bevel cutting machines stiffening beams and finalizing of the panel structures. Another feature is the simultaneous blasting/grinding for automated welding preparation and sheet mark- Panel lines can be integrated directly into the yard’s and plasma marking with the plasma marking torch, ing. Several shipyard enterprises became our global design- and manufacturing-data systems. Modern panel which can rotate automatically around the blasting head partners and enthusiastic cooperators in development lines produce high-quality prefabricated components to enable marking in different directions. of new solutions that make their production more and subassemblies that allow for high-speed welding, reliable, safer and efficient in the long run. Among even utilization of hybrid laser welding processes. Plates of varying thicknesses, which make up the panels, equipment and automation solutions developed for and the welds between them require complex control the demanding shipyard environment were: automatic MicroStep was chosen to deliver the cutting part of pan- of the plasma cutting process. Metal plates of different plate alignment via laser sensor, management of el lines – a robust DRM-PL gantry with effective cutting thicknesses require different cutting parameters such as working zones of cutting machine with an interface widths as big as 24 m. Apart from the sheer machine cutting speed and current. The borders between differ- for an external automatic crane for automatic loading/ size that implies high-end design and manufacturing ent sheet thicknesses are linear with surface inclinations unloading of material, barcode and QR code marking, coupled a powerful drive-motion system, the peculiarity ranging from 1:4 to 1:3 so the parameter change is not Machine Production Management (MPM) software in this case is in the technology: the thickness of the sudden but linearly interpolated. The most complicated suite and also our well-known ACTG® system for au- panel as well as its surface levels can vary as the single issue with these machines is cutting height control. The to-calibration of beveling tool stations. plates comprising the panel are of different thickness. classic height control according to measured arc voltage Besides the usual cutting heads (plasma or oxyfuel rota- is not enough in this case. If the border is on the top But it wasn’t until 2014 that MicroStep was able to tors) which enable bevel cutting of V-, X-, Y- and K-cuts, side of the panel, the cutting height is controlled in a ro- participate in the shipbuilding’s premium cutting DRM-PL machines are equipped with a blasting or botic mode according to the defined shape of the weld. application – automated panel lines. Thanks to the part- grinding unit and a marking tool. Blasting head is used After a transition to a new thickness, new parameters nership with the globally operating Finnish welding and to clean the primer from certain areas on the workpiece first need to be measured by the control system and production automation provider Pemamek, whole new where, subsequently, stiffening beams are welded. only then the height control according to arc voltage application horizons have opened up for MicroStep. can be turned on again. Furthermore, when crossing The blasting head has an integrated plasma marker welds, the height control needs to be deactivated so Cutting of large-scale welded panels to mark synchronization lines for future positioning of that the cut contour is not deformed. the stiffeners. Finally, an inkjet marker is used to print One of the prominent manufacturing application areas descriptions and technological marks.

MicroStep‘s panel cutting machines are capable of cutting large-scale parts with dimensions up to 24 x 24 m, inkjet marking, plasma marking as well as primer removal via sandblasting or grinding technologies. 34 Here come the robots Robotic pipe cutting A broad portfolio: More flexibility for the Jan De Nul Group: An innovative combination From robotic of plasma plate cutting and oxyfuel cutting of pipes by a robot

A robotic arm on a gantry-type CNC plasma and oxy- workplaces to fuel cutting machine capable of cutting both flat plates and pipes with the same gantry? Even if it’s not the first of its kind in the lands of Benelux and beyond, it is robots for cutting still an exceptional and highly innovative combination of high-quality cutting technology. For MicroStep, this newly developed solution has proven to be an eminent of 3D shapes success.

There are companies that everybody has heard of, even MicroStep‘s continuous activity in the area of robotic the people who don’t follow the Belgian industry sector. applications has resulted over the years in a com- This is often due to an article in the newspaper or a prehensive product line of components for robotic report on the TV about a success story which illustrates working cells – different types of workpiece position- the strength of Belgian companies abroad. You may ers, gantry-type and cross-beam motion systems and remember the name Jan De Nul from the mega dredg- standardized modular welding cells have been part of ing project in Dubai or the new Suez Canal in Egypt. the portfolio for many years. Robots have been used However, Jan De Nul Group is more than just a dredging for manipulation, welding, cutting or routing as part of Apart from mechanical challenges with integration of machine. So here‘s the trick: to ensure desired operating company. They have four main areas of interest: dredging a work sequence in production lines or as standalone robotic arms into CNC cutting machines, the main job is properties, MicroStep has developed its own control and marine works, offshore services, civil works and, final- cells. to be done by control system developers. Robotic arm modules for robots within the iMSNC control system, ly, environmental works. The JDN Group has grown into brings a whole different type of kinematics, a few more which cooperate flawlessly with the rest of the system. a global player by continuous investment into these four Furthermore, apart from designing robotic and semi-ro- driven axes and requirements for controlling the cutting The solution takes into account mechanical tolerances activities. In 2015 the group took over the foundation botic workplaces to automate various production technology. Besides the robot itself, the machine can of the individual robot joints as well as its movement expert Soetaert NV in order to strengthen its expertise in processes, MicroStep‘s engineers have been increasingly contain also other, standard, tool stations with various specifics arising from the robot‘s construction. hydraulic engineering and foundation building. intrigued by the vast movement possibilities of robotic straight/bevel cutting, drilling or marking technologies. arms and their potential to be utilized as carriers of In order to achieve seamless switching between cutting Solutions with robots Unburdening its customers: Everything from design up cutting tools on gantry-based CNC cutting machines heads, the control of the robot has to be integrated into to execution is being taken care of – especially in the field of structural steel applications the control system of the CNC machine responsible for MicroStep‘s projects with robots so far include turnkey such as cutting of beams or domes. This area is being all the mechanical modules of the system. Even though applications such as welding of frames of tower cranes, A success strategy is supported by many pillars but one gradually developed. robotic arm manufacturers supply their products with ATVs and snowmobiles, welding of high voltage ca- of the most important ones is “unburdening the custom- genuine control systems, their implementation may pacitors, transformer tanks and conveyor rollers as well er”. In the past, work was based mainly on following the Integration of robots: Apart from mechanical chal- present several obstacles, such as incompatibility of the as milling of plastics, luting, relocation of aluminium customer’s specifications; today, customers are looking lenges the main job is to be done by control system communication interface, too low refresh rate of the casting molds, a test cell for a partial simulation of a rather for a complete solution to their problem. The “Furthermore, materials thicker than 25 mm had to be cut developers desired effector position, insufficient feedback speed or production line, automated cutting of ceramic tanks, multidisciplinary teams of Jan De Nul Group follow the with oxyfuel technology which was much slower.” issues of coordination with other movement axes of the cutting of coupons from hot-rolled steel and others. integrated approach – everything from design to exe- MicroStep delivered the complete cutting solution: with a cution is being taken care of with their own people and 12 x 3 m cutting area for plates up to 150 mm thick and a equipment. Some projects even include maintenance and zone for cutting pipes with a robot situated along the out- financing. A customer always gets a creative and inno- er side of the machine guidelines, the machine is capable vative solution tailored to their own specific needs. This of processing tubes up to Ø 2000 mm and wall thickness endeavor is supported by a large design and engineering 80 mm. The challenge here was to ensure cutting and department which serves all four areas of interest. positioning of pipes in the entire required range of diameters (Ø 100 – 2000 mm) and thicknesses and, at the same time, to propose a technical solution that would allow the Continuous investment into new technology and most convenient manipulation of pipes while requiring equipment MORE EFFECTIVE minimal construction interventions in the production hall. An equally important part of the strategy is continuous The final solution was an oxyfuel torch on a robotic arm, DUST COLLECTION investment into new technology and equipment. Let’s as this provides high movement flexibility and isn’t limited illustrate this by looking at JDN’s own fleet. It consists by the height of the gantry. This way it was possible to MicroStep delivered the complete cutting solution: with a 12 of more than 85 ships, 47 of which were built between place the pipe cutting tracks and supporting rollers on the FOR THERMAL CUTTING x 3 m large cutting area for plates up to 150 mm thick and a 2007 and 2013. Bigger isn’t always necessarily better floor level without the need to “sink it” underground. For Certified in zone for cutting pipes with a robot situated along the outer but for large-scale international projects that became compensation of possible deviations of the pipe shape, APPLICATIONS compliance side of the machine guides, the machine is capable of proces- JDN’s specialty, it is an asset that cannot be underes- a laser scanner integrated in the torch holder is used to with ATEX sing tubes up to Ø 2000 mm and wall thickness 80 mm. timated. The group works with world’s largest trailing scan the surface of the pipe in the place of the cut will suction dredgers, the sister ships Cristóbal Colón and Leiv be. If any deviations are detected, the cutting program is automatically adjusted. The use of a scanner in com- When it comes to the use of dust collectors for thermal cutting Eiriksson with hopper capacity of 46 000 m3 and depth range up to 155 m, as well as the subsea rock installation bination with a sophisticated robot movement control applications, the DFPro range sets a standard that is considerably higher vessels Simon Stevin and Joseph Plateau which are the (compensating for the existing inaccuracies of the robot’s most powerful vessels of their kind. construction) and the dedicated 3D CAM software mCAM in efficiency and performance. The high performance at low operating achieves accurate openings and contours of different ® shapes. The pipe cutting zone is equipped with a safety costs is a result of the innovative filter media Ultra-Web in high- “We think that we can make complex parts best by light barrier which turns on together with the robot to ourselves.” performance filter cartridges. The Ultra-Web Flame Retardent filter ensure operational safety. media meets the BIA classification M. Integrated More remarkably, Jan de Nul is one of the few dredger “First of all, the plasma/oxyfuel cutting machine with the integrated robot has resulted in considerable time savings preseparation systems provide additional safety against companies that design their vessels and equipment themselves. There are good reasons for this. “First of all because all the weld preparation is now done automati- flying sparks. The DFPro range is available for extraction you have better control over the delivery times and there cally and in one step, which also increases quality. As to the pipe cutting, not only has our reach been increased, volume flows of 2.000 to 16.000 m3/h. is also the quality factor. We produce many complex parts of unusual shapes and that requires a great deal of but we can also cut any shape. In terms of flexibility, we know-how. We think we can make these complex parts have improved significantly,” José Pycke concludes. best by ourselves. Furthermore, this knowledge you want to keep in your own house and not outsource,” says Jose Pycke, Workshops Manager for Jan De Nul Group. 70 op- Jose Pycke erators work in the production department. It is divided Workshops Manager into a material preparation area, welding workshop and Jan De Nul Group Scan me to find out machining workshop equipped for processing of very more about the DFPro series large parts. The largest vertical lathe can handle parts with a diameter up to 5,5 meters. “The plasma/oxyfuel cutting machine with The complete cutting solution from MicroStep integrated robot has resulted in considerable time

“Our old oxyfuel cutting machine was still functional, but saving because all the weld preparation is now we couldn’t do weld seam preparation with it. We had done automatically and in one step which also Discover our range on www.donaldson.com to do the bevels manually with a hand torch or an angle grinder, and that took a lot of time. The machine from increases quality.” Shop for filters the easier way at shop.donaldson.com MicroStep solved this problem,” says Mr. Pycke. Contact us on [email protected] 37

Donaldson DFPRO Microstep GB.indd 1 11/09/2018 09:48:43 EXTRA: Machine Production Management (MPM): Automating the production process on cutting machines

Machine Production Management (MPM) software with customer‘s ERP system (e.g. SAP, AXAPTA). For ef- ment of Cutting Plans) and information about what kind suite provides computer-aided process planning fective production planning, the system provides weight and amount of material was used is forwarded to the (CAPP) features for automation of the workflow on analysis of particular orders along with weight reports of storage database. CNC machine(s) or production lines. It is an integrated actual stock resources. MPM and loaders are universal systems that can be system of order processing, nesting, stock manage- configured to suit the specific manufacturing process ment, machine operation planning and evalution The primary target group for MPM application are busi- exactly according to the customer‘s needs. Operation 24/7: The automated cutting line (left) at ZMJ is which interconnects pre-production data, control nesses with multiple cutting machines, e.g. job shops or controlled from a central control room (above). A total of eight systems of CNC machines and MicroStep‘s automatic large steel processors in various industries (shipyards CNC plasma cutting machines from MicroStep are automati- nesting software AsperWin®. It helps to reduce work- and offshore, energy, agricultural, automotive and cally loaded and unloaded by a Demag process crane. in-progress, to save material, and to eliminate opera- others). One of the main benefits of this system is the tor errors. automated task allocation for multiple machines based on priorities and technology availability. A substantial part of MicroStep‘s product portfolio is focused is on high-end customers with large production The system offers a unique feature of providing feed- facilities, who put emphasis on efficiency and a high lev- back to the database after cutting: if specific parts have el of automation. Complying with these requirements, been cut incorrectly, the operator can identify them MicroStep offers an in-house developed CAPP applica- directly on the control screen. These parts are automat- tion called MPM (Machine Production Management), ically returned to the order database and assigned the which is an integration platform for different areas of highest priority in the next nesting so that the order the business – material storage, order management, is completed as soon as possible. Processing status of creation of cutting plans, and CNC machines operators, each order or part can be monitored in the database in allowing automation of information flow among them. real time. This feedback feature is unique to MPM; it is not present in comparable systems on the market and MPM software is primarily aimed at facilitating efficient is possible only due to the integration of the control 40 percent production increase machine use. Used to its full potential, the machine‘s software iMSNC® with the CAM software AsperWin® or interface offers the operator a cutting plan together mCAM, all in-house developed by MicroStep. Example: Danish producer benefits from MPM with the location of the specific material (plate, pipe…) in the warehouse. Operator‘s task is to place the ma- Integration with material loading systems Real-life example: Two MG plasma cutting machines for MicroStep and Terex have supplied an automated production terial in the working zone of the machine, synchronize Danish metalworker Multicut also represent an innova- the coordinate system with the semi-product‘s spatial MPM features also a direct link to automated material tive solution for automatic loading and unloading. Each orientation (which can be automated by finding of the loaders. The machine compares the cutting plans with of the 21 m long machines is divided into two separate material edge by a laser sensor), install the required the inventory of the warehouse and determines what cutting zones. Cutting is always done in one zone while line for the Chinese mining equipment manufacturer ZMJ consumables and start the cutting process. All necessary is going to be cut. Based on the information received, the other zone is used for unloading of cut pieces and parameters are selected automatically, based on the it requests the needed types and amounts of material subsequent loading of new material – subsequently, the MicroStep and Terex MHPS GmbH (manufacturer of solution also ensures that the machinery is utilized to a thick) by means of strong magnet spreaders onto a free information contained within the cutting plan. When from the storage. A warehouse operator brings the ma- zones switch. The active cutting zone is always secured Demag industrial cranes) in a pioneering tandem: in consistently high level. The impressive result of this pilot in- machine or into one of two buffer zones assigned to each using an integrated loading system, the machine also terial to the machine where it is loaded to the loading by the system that guarantees maximum work safety. close cooperation, the companies developed a material stallation: production in the entire plant has been increased of the eight CombiCut machines. After the cutting process, loads the semi-product into the cutting area and can position and the rest of the process is fully automated: The machines identify the material by themselves, using handling system for automated sheet metal processing by 40% with a monthly machine output of 12,000 t. the crane moves the cut plate onto an output conveyor also facilitate the unloading of finished parts. The loader loads the sheet into the machine. The ma- a built-in QR code scanner. for China’s leading coal mining equipment manufactur- belt. Here, the plates leave the automated area and pro- chine can then check whether it is the required material er Zhengzhou Coal Mining Machinery Group. In total, General trend towards automation ceed to be sorted out manually. Although designed for MicroStep machines with by using a built-in thickness sensor or by scanning a MPM is a comprehensive system of automation of the ® ® eight MicroStep plasma cutting machines are being fed AsperWin CAM and iMSNC control systems, MPM barcode or QR code printed on the material. After the production cycle on cutting machines. Along with Mi- with plates by an automated Demag process crane from This project reflects the current trends in the field of indus- An area measuring 120 x 18 m was fenced off within also offers possibilities of cooperation with third party cutting process is complete, the machine sends informa- croStep machines, it has been already deployed in more Terex. As a result, immense efficiency gains are achieved trial mass production. Increasingly, solutions with central the production facility for the storage and processing of machines. Naturally, the production data can be shared tion about what was cut to the MCP module (Manage- than thirty businesses in Europe, Asia and South Africa. in the production process. production management and a high degree of automation plates. Here, the customer not only benefits from a better are in demand. The goals are: the highest possible efficien- organized flow of material, but also from improved safety The Chinese mining industry is booming and so is the cy, optimization of the production process and, of course, at the workplace: a dedicated access concept prevents any mining equipment sector. The Zhengzhou Coal Mining reduction of risks and costs. The whole production should personnel from entering the individual processing areas Machinery Group is one of the market leaders both for be fast, smooth and transparent. In addition to material when they are automatically approached by the crane. stationary equipment for roof and long-wall supports as flow and material processing, the system should also be When routine maintenance work is performed on one of well as for mobile machinery that operates in mines. At interconnected with the central warehouse, order manage- the cutting systems, the automatic crane by-passes the its plant in Zhengzhou, the capital of Henan province, the ment system and the customer‘s ERP system. danger zone in order to protect the personnel. company is running a production line for automated plate processing consisting of several double-gantry MicroStep The automatic line installed at ZMJ consists of eight cutting machines and a Demag process crane, which is CombiCut gantries with cutting areas of 28 x 3 m, each responsible for storage and retrieval of the plates as well equipped with two high-definition plasma sources and an ZMJ as the feeding of the cutting systems in a 24/7 operation. inkjet marker. In addition, there is an automated overhead Video presentation: At the heart of the system is the production management crane (9 t x 16.5 m), an input wagon with a load capacity of software MPM from MicroStep, which controls the entire 15 t and two output conveyors for collecting the cut parts production process. and removal of waste material. The entire line is fully automated via MicroStep‘s Machine Production Management The investment has paid off for ZMJ: Every day, the cutting (MPM) software, with integrated software modules from line is able to process up to 155 metal plates in three-shift Demag for crane management and material handling. operation, with one production cycle now taking only The crane is moving on a 120 m long track in the height one to two hours, compared with the four to eight hours of almost 13 m. In the beginning of the process, the crane www.microstep.eu/video previously. The intralogistics system implemented for this transports one of the plates (up to 12 m long and 40 mm

EXTRA: Management of the entire production process via MicroStep’s MPM software

The entire production is controlled by MicroStep‘s production management software MPM, with integrated control software of the crane (WMS) and conveyors. Through MPM, every production 5 step is coordinated and run automatically. Therefore, no active intervention from the operating personnel is required. The parts 3 to be cut are automatically nested by MicroStep‘s proprietary 2 CAM software AsperWin® (nesting = material-saving distribution of parts on the plate by nesting algorithms in order to utilize the material to the maximum via minimizing waste), and after nesting, 1 the corresponding cutting plan is generated for a particular plate from the stock. Generated cutting plans are then distributed to the individual CNC plasma cutting machines through MPM‘s MCP module. The crane automatically supplies available cutting machines with plates, based on information received from the material loader and iMSNC® control systems of the particular machines. The position and orientation of the plates on the cutting tables is 4 measured automatically by a laser sensor. Also, the cutting process is carried out fully automatically. After cutting, the cut parts and residual waste are moved by the magnetic crane to either of the two output conveyors. In this case, machine operators are serving only as supervisors and service technicians, for example to replace 1 Material input (wagon) 2 Automatic crane 3 Control room worn consumables. 4 CNC cutting machines 5 Output conveyors

38 Machine series | The right machine for every cutting task

Plasma Oxyfuel Plasma Oxyfuel Drilling Plasma Oxyfuel Plasma Oxyfuel

MG DRM MasterCut MasterCut Compact MG is MicroStep‘s top-class CNC cutting machine suitable for long-term industrial use while meeting DRM is a heavy-duty CNC cutting machine designed for a wide range of dome, plate and pipe MasterCut is a versatile high-precision CNC cutting machine which can be applied throughout the MasterCut Compact is a dynamic, high-precision CNC cutting machine suitable for a variety of plas- highest requirements on precision, performance and ease of operation. MG machines are suitable for a cutting applications. Its robust gantry allows a vibration-free operation of heavy equipment such as industry reaching from small workshops to big factories. The standard version with rails in the X ma and oxyfuel cutting jobs. Thanks to its sophisticated design it smoothly delivers latest features of variety of applications such as bevel cutting with plasma and oxyfuel, additional beveling process (ABP), automatic oxyfuel triple torches or a 120° rotator with Z-axis stroke 1,500 mm for cutting of dished direction can be enhanced to a variety of high-precision plasma cutting applications including pipe, plasma technology for a decent price – true contours, small holes, sharp corners. An optional bevel pipe, profile and dome cutting, drilling and marking. ends. DRM can be delivered also as a high-performance drilling machine with special drilling table. profile or elbow cutting and marking. cutting tool station allows to perform a great portion of common bevel cutting jobs.

Drilling Plasma Oxyfuel Plasma Oxyfuel Plasma Oxyfuel Oxyfuel Plasma

DS CPCut & PipeCut ProfileCut CombiCut DS is designed for high-efficiency drilling and cutting with the possibility of automatic plate feeding and MicroStep‘s pipe and profile cutting solutions are designed for processing of a great range of pipe dia- ProfileCut is a machine dedicated for production of steel structures. Besides optional pipe and plate This robust, high-precision CNC machine is designed especially for multiple-shift high-performance automatic part sorting on output. The plate processing line is dedicated to heavy-duty structural steel meters and lengths. The machines´ modular design enables a wide range of pipe-based applications cutting zones, ProfileCut‘s main cutting area is dedicated to processing of structural beams such as I, plasma and oxyfuel cutting. It allows cutting of steel up to 300 mm thick, bevel cutting with a pair of applications such as high-precision fittings, gussets and endplates. The machine is designed for a high including trimming, cutting of various openings for multiple pipe and profile intersections or connec- H, U or L. To enable precise division as well as cut-outs in required spots on the beam, the machine is oxyfuel triple torches or rotators, parallel cutting with up to 8 torches, drilling up to Ø 40 mm, inkjet, level of automation within the factory workflow. tions, weld edge preparation as well as pipe marking. equipped with a laser scanner for measuring of the true shapes of beams. micro-percussion or laser marking, as well as pipe and dome processing.

Laser Laser Laser Plasma Waterjet Plasma

MSF Compact MSF MSF Max AquaCut MSF Compact combines precise 2D laser cutting with a compact design. Available in work area sizes of MSF is a powerful fiber laser cutting machine designed for the production of highly accurate parts at MSF Max is a fiber laser cutting machine designed for precise processing – including efficient bevel AquaCut is a versatile waterjet cutting machine designed for processing of a wide variety of materials 1,000 x 2,000 mm, 1,250 x 2,500 mm and 1,500 x 3,000 mm, this highly precise machine is particularly high cutting speeds, with surprisingly low maintenance and operational costs. The machine is equipped cutting – of large-sized components. The machine offers an extensive production versatility, including including those that cannot be subject to thermal or mechanical stresses. The machine can be equip- attractive thanks to its small footprint. A manually extractable cutting table enables easy and straight- with an automatic shuttle table up to the size of 12 x 3 m. The optional equipment includes pipe and 2D cutting, bevel cutting up to 45°, drilling up to Ø 30 mm, tapping up to M20, countersinking and ped with a 5-axis waterjet rotator, as well as combined with plasma cutting, pipe and profile cutting forward loading. profile cutting, and drilling, tapping and countersinking. marking. or tapping. Further features include ABP technology and taper compensation (ABC).

40 41 Accessories | The right tool for every ta sk

2D cutting Automation & Calibration Drilling

Plasma Laser Oxyfuel | G-Multi Waterjet | W-Multi ACTG | ACDB Nozzle calibration Nozzle changer Drilling & tapping

ACTG station provides auto-calibration of A combined station for automatic cali- Automatic nozzle changer with a magazine MicroStep supplies a variety of drilling and tool geometry for automatic compensation bration of capacitive height sensor in the for 8 nozzles provides the function of tapping tool stations – from small drilling of mechanical inaccuracy of the cutting laser cutting head, brush cleaning of laser automatic exchange of nozzles in the laser heads for soft sandwich materials to big Plasma tool station incl. anti-collision protec- Laser tool station for fiber laser 2D Oxyfuel tool station with manual tilting Waterjet tool station for cutting of all types tool as well as calibration of ABP scanner nozzle and a camera to check the status of cutting head. drilling and tapping units with internal tion, laser pointer, arc-voltage THC and full cutting. possibility up to ±45°. Fully automatic gas of materials. Multi-tool version can carry and automatic measurement of drill tools. nozzle orifice. cooling of tools and various automatic tool support of plasma marking. console with preset parameters ensures up to 4 water jets on a single Z lifter. changer options. stable quality of cuts and best efficiency. Multi-tool version enables stripe cutting with stripe width ≥ 70 mm. 3D cutting Positioning Scanning

CCD camera | Automatic ABP - Additional Plasma rotator Plasma 3D rotator Plasma bevel Laser bevel Pipe & profile 3D scanner plate alignment beveling process

Pipe cutting device is dedicated for clamp- Laser scanner with a rotation and tilting CCD camera can be used for: ing and turning of pipes and profiles. To- ability allows to create detailed surface a) scanning of the shape of template or rest gether with a straight or bevel tool station representations of scanned objects – e.g. plate for conversion into DXF 3D rotator with a tilt range up to 120° Plasma bevel cutting head with a tilting Laser bevel cutting head with tilting ability and dedicated CAM software it offers the profiles and domes. In combination with b) scanning of holes on plate for positioning and Z-axis stroke up to 1,500 mm enables ability up to 50° allows to perform a great up to 45° for fiber laser cutting of various full range of pipe cutting applications. mScan technology it allows to adjust cut- A laser sensor is used for scanning of plate cutting of 3D shapes such as open profiles portion of common bevel cutting jobs. types of materials. ting plans according to true shape of 3D edges for auto-alignment with the coordinate I, H, U or L and domes. objects. system. Marking

Oxyfuel triple torch Oxyfuel rotator Waterjet rotator Inkjet MicroPunch Laser marker

Laser scanner dedicated for scanning of both the contour and position of a straight pre-cut part in ABP feature – additional 5-axis rotary bevel head with endless Oxyfuel triple torch with fully automatic 5-axis rotary bevel head with endless 5-axis rotary bevel head for waterjet en- 1, 7, 16 or 32-nozzle inkjet writer provides MicroPunch marking unit is designed Laser marker allows to mark text, barcodes, cutting of bevels for weld edge prepa- rotation enables plasma bevel cutting of gas console enables bevel cutting of V-, rotation enables oxyfuel bevel cutting of ables bevel cutting of all types of materials multipurpose waterproof marking in indus- for micro-percussion marking of plates, 2D matrix codes and bitmap images with ration. ABP technology is available for plates, pipes, profiles and domes up to 52°. X-, Y- and K-cuts with 3 oxy torches within plates, pipes and profiles up to 65°. The in- up to 45°. Adaptive taper compensation trial environment. It can write lines, char- pipes or profiles with differently machined fiber laser. plasma, laser, oxyfuel and waterjet cutting The innovative ITH torch holder includes bevel range 20° – 50°. Tilting angle and novative ITH torch holder includes sensors (ABC) and periodic height sensing (PHS) acters, barcodes or 2D matrix codes. The surfaces. technologies. sensors for torch displacement detection, span of torches can be set manually or for torch displacement detection, IHS and are included by default. marking speed reaches a notable 20 m/min. IHS and auto-calibration. automatically. auto-calibration.

42 43 Dr. Alexander Varga: We are currently being repre- blasting solutions that prepare places where stiffeners will investment activity is focused on the production infra- sented by more than 40 dealers active in 55 countries be subsequently welded. Our customers are renowned structure. In 2011 our administration and development worldwide. These companies aren’t responsible only for companies like ThyssenKrupp, Bosch, Doppelmayr, Viess- center in Bratislava was finished and it was followed by the sales but also for the service and maintenance. The mann, Lürssen and others. renovation of production facilities in Partizánske and most significant is our representation in Germany by our Hriňová. In 2017 we built a new assembly hall in Partizán- subsidiary MicroStep Europa GmbH, which sells approxi- The history of MicroStep in its nearly three decades is a ske. Now we are planning to further expand the produc- mately 30 % of our yearly production in Germany, Austria story of success. Where do you think has been the starting tion halls in Hriňová. We are also continually expanding and Switzerland. European market is the one where we point for this fruitful run and what is in your opinion the the equipment of our factories. We are currently in the have the strongest presence and are able to sell the most long-term trend and prognosis for the future? process of implementing an advanced project manage- complex solutions. We also have strong representation ment system. in Russia and China and are currently starting business Dr. Alexander Varga: The beginning of our evolution activities in USA, Canada and Australia. from a small university-based start-up to a worldwide What are your other goals and plans company happened 1997 in for the future? With the slogan “Your Partner Essen, Germany. At this time, for Cutting and Automation” we managed to get ourselves – Dr. Alexander Varga: Our main you offer a wide portfolio “Every customer together with other companies goal is to strengthen our position ranging from small solutions from Slovakia – and with one among the top producers of for schools or workshops to cus- of our simplest machines – into energy-beam cutting machines. It tomized automated production is important to us an exhibition stand at the in- is a long-term continuous process lines for steel centers, shipyards ternationally recognized Weld- of building up a good production or the automotive industry. and we approach ing & Cutting fair. There we base, good development teams, steady Could you name some of your made first contacts with po- product improvement and a qualified most prominent customers? Are tential customers and also with dealer network. there any unique projects you his machine order potential dealers. Gradually the managed to realize recently? number of produced machines responsibly. “ increased and these machines Dr. Alexander Varga: Every needed to be serviced and so single customer is important naturally, a subsidiary company to us and we approach his was founded in Germany Alexander Varga, Ph.D. machine order responsibly. Im- Head of R&D (MicroStep Europa GmbH) re- portant category of customers MicroStep sponsible for sales and service. who need heavy-duty ma- Later others were founded. The Invest in innovation and production chines are shipyards. We have first one mentioned is the most delivered several solutions for established and sells more this segment recently. One of those is a large-scale CNC than 60 machines every year. Here lays the basis of our Dr. Alexander Varga attending the fiber laser cutter 50 m long and 3.5 m wide for Chantiers business success story. Today we produce approximately finals of EY World Entrepreneur of de l’Atlantique (until recently STX France - see page 28). 180 CNC machines while 95% of the production is sold the Year™ in Monte Carlo in 2015. Dr. Alexander Varga, co-founder and MicroStep’s R&D chief The machine powered by an 8 kW solid-state fiber laser abroad. During the existence of MicroStep, we have sold Together with Eva Stejskalova source and equipped with a bevel head. Other significant over 2,500 machines into 55 countries worldwide. he was national winner of the solutions are plasma cutting machines delivered to Irving We have the development and administration center in EY Entrepreneur of the Year™ about the beginnings, a fruitful run and goals Shipbuilding shipyard in Canada, Vard Tulcea shipyard in Bratislava (SK), production facility in Partizánske (SK) and prize awarded by the renowned Romania, German Naval Yards in Germany with others on production facility in Hriňová (SK). consulting company EY for their achievements with MicroStep. Nowadays, it is said that worldwide industry has to move thanks to the technological level of our solutions. This technology is suitable for cutting materials up to 25 the way. These machines are a part of lines for produc- Where did you invest most recently and what projects are away from simple assembly and production towards The cutting technologies are constantly developing mm thick. For our laser machines we use IPG (USA) laser tion of large-scale panels used for shipbuilding delivered you planning for the future? higher added value, development and innovations. Your mostly in terms of cut quality, accuracy, cutting speed sources. by Finnish company Pemamek with MicroStep being a company did just this in its beginnings, you were focusing and maximum cut thickness. As these parameters subcontractor. Working areas of these machines range up on the development of special applications and the pro- improved, the thermal cutting started to push conven- Waterjet cutting on the other hand is most suitable in to 24 x 24 m. Apart from bevel cutting with plasma they Dr. Alexander Varga: Apart from investments into duction came about later. What products and services do tional machining technologies out of many production cases when thermal cutting isn’t an option or when are equipped with inkjet marking and plasma marking/ development and innovation of our entire portfolio, our you offer at the present? areas. If the part is cut with high accuracy, it doesn’t required materials can’t be cut by other technologies have to undergo any further machining. High quality (rubber, plastic, etc.). These machines are equipped Dr. Alexander Varga: Focus on our own develop- plasma, fiber laser, waterjet and CNC machines can cut with high pressure pumps from Hypertherm (USA), KMT ment has been determined by the professional past of parts with beveled edges ready for subsequent welding. (USA) and BFT (AT). MicroStep’s founders. MicroStep was founded in 1991 Machines with drilling heads allow drilling, tapping and The oxyfuel cutting technology is dominating in the by 10 researchers and teachers from the Department countersinking. Parts can be also marked by different field of very thick materials usually cutting metals up to of Automation and Regulation, Faculty of Electrical technologies (laser, plasma, inkjet, micro-percussion). 300 mm thick. Engineering and Information Technology of the Slovak We can clearly see it is not only about the cutting but These days, the cutting technology itself is not the University of Technology in Bratislava. Our goal was to about complex part preparation and such machines are primary concern for our customers anymore. More and continue working within our expertise which was accu- basically complex production centers. If we add systems more they want automation solutions with automatic rate digital servo systems and microprocessor controlled for automatic loading/unloading and sorting of the cut loading, unloading, sorting of the cut parts, fully au- technology. We wanted to produce in-house developed parts, it is an automated production cell. This is exactly tomated production cells connected to higher level of control systems for applications which require accurate the kind of product we deliver. We also provide service production management which fit into the recent global positioning control. Slowly, we worked our way to CNC for our machines; each is equipped with remote diag- trends known as IoT and Industry 4.0. plasma cutting machines and gradually we expanded nostic software. our portfolio with other cutting technologies – oxyfuel, Apart from development and manufacturing of new waterjet and laser. Time has shown us that with sophis- MicroStep is a producer and supplier of CNC machines products you also develop your own software with spe- ticated products, it is possible to succeed even on a for cutting by plasma, laser, oxyfuel and waterjet. What cialized modules for particular machining applications global scale. Over the years we have developed quite are the latest trends and requirements of your customers and thanks to that you are able to offer a wide portfolio large portfolio of products for CNC cutting and offer in this area? Which technologies appear to be the most of products and services to your customers. What is it that both complex high-end and simpler low-end applica- perspective? makes MicroStep different from its competitors? What do tions. Our machines are conceived in a way which allows you consider to be strengths of your company? different cutting technologies and additional technolo- Dr. Alexander Varga: Each of the mentioned technologies like drilling, tapping, countersinking, marking etc. gies has its place and I don’t believe one will be pushing Dr. Alexander Varga: Software products are an integral to be installed on a single the other out, even though part of our systems. MicroStep doesn’t deliver only ma- machine. The traditional flat- application areas of for chines; we deliver a complete workplace which includes bed cutting machines can be example plasma and laser do the cutting machine and software for creation of NC extended with equipment overlap a little. Over the last code. The software nests the parts in a way which leaves for cutting of pipes and pro- “MicroStep doesn’t 20 years, the plasma technol- minimal amounts of waste, adds lead-ins, lead-outs, de- files of different diameters, ogy has gone through huge fines cutting priorities etc. In case the unit is equipped or different 3D objects (e.g. deliver only machines; development. Today, it is pos- also with automatic loading and unloading, the software tank ends for pressure ves- sible to cut metals up to 50 is responsible for the entire process. We develop all of sels). Our high-end machine mm thick and still maintain the software ourselves. Naturally, there are customers types have a modular con- we deliver a complete high quality. We equip our who create their cutting plans using software from a struction and the actual size machines with plasma sourc- different producer, but we are able to adapt also in this as well as the technology es from Hypertherm (USA) case. Thanks to the entire system being in our hands, we setup are made according to workplace.“ and Kjellberg (DE). Both of are able to offer solutions our competition can’t. A great customer’s needs. Smallest these companies represent example of that is a special machine for a customer machines come with work- the top in their field. Howev- from Belgium. Apart from standard plasma cutting head ing area of 3 x 1.5 m and the Alexander Varga, Ph.D. er, when cutting thin mate- there is a robot functioning as another cutting head Head of R&D biggest ones are 50 x 10 m MicroStep rials with fine details, plasma for cutting pipes up to Ø 2,000 mm (see page 37). The large, and even large sized will never reach quality of main strength of MicroStep is a strong, experienced and gantries providing effective laser cutting. Laser cutting capable development team which allows us to create working widths of more than too has been going through tailor-made machines. Many of our competitors can’t do 20 m. Our machines are fit- period of rapid development. that and our customers greatly appreciate this fact. ted with high quality linear guidelines from THK, Bosch CO2 lasers have been swiftly replaced by solid-state fiber Rexroth and HIWIN, servo motors and controllers from lasers which transfer the laser beam into the cutting Your success is highlighted by the fact that you managed Panasonic, pneumatic accessories from Festo etc. These head via optical fiber. That enables simpler construction to succeed abroad where you have representation in top quality parts assure long term reliability of our of large-scale laser cutting machines without the need many countries. Where in the world do you operate and machines. We have made a name for ourselves mainly to place the laser source directly on the machine gantry. in what markets do you have the strongest presence? 44 The MicroStep World Present in more than 50 countries worldwide

Alex Makuch Managing Director MicroStep | Your Partner for Cutting and Automation MicroStep

Through a network of authorized representatives, MicroStep is present in 54 countries. More than 90% of our production is destined for The MicroStep Group export. Apart from our home market – Slovakia – and almost all European countries, MicroStep cutting machines also operate in the USA, Canada, China, Russia, South Africa, the Middle East, India and Australia. In the field of plasma cutting, the company belongsamong the “Our success would not world‘s largest producers. State-of-the-art solutions for processing of plates, pipes, profiles, be possible without Contact the MicroStep strong partnerships with representative in your beams and domes area to discover the variety of MicroStep‘s our suppliers and, most products and features! Activities of companies associated in MicroStep Group workplaces that combine different cutting/drilling/mark- va and the Institute of Materials & Machine Mechanics importantly, without the range from development, production and sales of CNC ing technologies in connection with automatic loading of the Slovak Academy of Sciences on utilization of latest cutting machines to supplying of control systems and and unloading systems, following the demands for high- achievements in design and control of machinery. profound commercial and software products for power industry, rubber industry, er level of machinery automation and interconnection of Thanks to its innovation driven production, MicroStep automotive industry and mechanical engineering com- control systems, CAM software and ERP systems. has become a valued partner for industry´s leading Our customers | Strong partnerships at a global level technical abilities of our panies. The parent company MicroStep, spol. s r.o. was manufacturers: Hypertherm, Kjellberg, IPG, HIGHYAG, established in 1991 by members of the Department of Core values of MicroStep – customer-oriented and fair Precitec, KMT, BFT, GCE, Harris in the field of cutting sales partners. Together we Automation and Regulation, Faculty of Electrical Engi- approach, continuous innovation and profound exper- technology; Bosch Rexroth, THK, HIWIN in the field of The technology of MicroStep and our long-term experience in the cutting and automation fields have helped us to build a user base neering and Information Technology, Slovak University tise – are rooted deeply in the company‘s culture linear motion components; Festo, Asco Joucomatic in spread across many different industries, from schools and small workshops to big multinational enterprises. The know-how of our make it happen.“ of Technology in Bratislava, Slovakia with the aim to the field of pneumatic components; Donaldson and Teka employees helped realize more than 2,500 cutting machines worldwide. We appreciate the trust of each of our customers, among others: develop and deliver microprocessor-based control As a technology and equipment innovator, the company in the field of filtration systems, Panasonic in the field technology to various branches of industry. Over the keeps introducing new solutions to the market on a reg- of motor controls and ABB, Fanuc and Mitsubishi in the years, the company has become one of the leading ular basis and holds several patents. In line with its long- field of robotics. suppliers of cutting equipment that supplied more term effort to establish automated CNC bevel cutting than 2,500 cutting machines worldwide in cooperation as a common production technology for preparation of with strong channel partners spread over 54 countries. weld edges on different types of materials, MicroStep‘s patented technology ACTG® – a system that reduces Multi-functional CNC Today, MicroStep is offering the full range of contempo- the setup time of a bevel head from hours to a couple rary cutting technologies – plasma, laser, oxyfuel, water- of minutes – has already been delivered with more than cutting machines jet – along with a great variety of supplemental equip- 400 systems and is proving its relevance in daily opera- ment and software for drilling, tapping, countersinking, tions worldwide. marking, process synchronization, automated material PLASMA – LASER – OXYFUEL – WATERJET – handling and robotic solutions. As a producer of not only Rapid growth of MicroStep over the years resulted in DRILLING – TAPPING – COUNTERSINKING – the machines themselves but also of control systems and founding of several domestic and international sub- MARKING CAM software, the company delivers solutions that fit sidiaries, most notable of which are MicroStep Europa ▪ custom demands and are future-proof with respect to GmbH in Germany, MicroStep USA, MicroStep Canada ▪ Processing of plates, pipes, profiles, beams machine extensions in size and additional technologies. and MicroStep China. Together with subsidiaries, the and domes Moreover, MicroStep’s machines can process different company has a total of over 500 employees, out of which ▪▪ Combinations of technologies on one machine types of materials including plates, pipes, profiles, more than 10 % are working in the field of integrated ▪▪ A wide range of accessories beams, domes or elbows while implementing advanced development of mechanical and electronic nodes of CNC ▪▪ Material handling & material flow automation automation processes. All of MicroStep’s machines are machines and control systems software. ▪▪ CAPP applications for production management controlled by iMSNC®, a multi-tasking PC-based control The company operates two production sites in Slovakia ▪▪ 2D & 3D CAM software system developed and produced in-house. in the towns of Partizánske and Hriňová. In addition to The focus of the company are hi-tech machines that its own R&D base, MicroStep works closely with depart- ▪▪ Robotic solutions accommodate industry‘s latest trends –fully automatic ments of the Slovak University of Technology in Bratisla- 46 47 Your Partner for Cutting and Automation

Complex & Multi-functional

There is hardly any other CNC system with such a variety of technologies provided by a single machine for such a variety of materials: sheets, pipes, profiles, beams as well as domes. MicroStep is offering such versatile and efficient solutions by nature.

See the cut sample above – bevel cutting of contours and openings, drilling, tapping, countersinking, punch marking and contour marking, all delivered in a fully automatic mode by our multi-functional plasma all-rounder MG.

And such versatility can be experienced in laser, oxyfuel and waterjet fields as well. For example, our modular fiber laser system MSF provides bevel cutting of plates and pipes along with drilling, tapping, countersinking, marking and automatic material handling options.

Contact the MicroStep representative in your area!

For more information visit: www.microstep.eu/dealers

NEW

Product Catalog Information on all MicroStep cutting systems can be found in our current product catalog. © 2018 Copyright & Design by MicroStep Europa GmbH – All rights reserved / Status 10/2018 – Changes and errors excepted Europa GmbH – All rights reserved / Status © 2018 Copyright & Design by MicroStep

MicroStep, spol. s r.o. · Vajnorská 158, 831 04 Bratislava, Slovakia · +421 2 3227 7200 · [email protected] · www.microstep.eu